LG Electronics Indoor Fireplace GC3 User Manual

INSTALLATION AND OPERATION MANUAL  
B-Vent Gas  
Fireplace Insert  
Retain These Instructions For Future Reference  
P/N 775,225M Rev. A, 06/2007  
A French manual is available upon request. Order P/N 775,225CF.  
Ce manuel d’installation est disponible en francais, simplement  
en faire la demande. Numéro de la pièce 775,225CF.  
In the Commonwealth of Massachusetts:  
• Installation must be performed by a licensed plumber or gas fitter  
• See Table of Contents for location of additional Commonwealth of  
Massachusetts requirements  
Firestar™ (GC3)  
Report No. 050-S-07b-5  
WARNINGS  
• Hot! Do not touch! The glass and surfaces of this appliance will be hot during operation and will  
retain heat for a while after shutting off the appliance. Severe burns may result.  
• Carefully supervise children in the same room as appliance.  
• Suitable for installation into masonry or factory built fireplaces. These appliances may be installed in an after-  
market permanently located, manufactured (mobile) home, where not prohibited by local codes. This appliance  
is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with  
other gases unless a certified kit is used.  
• Lennox™ gas-burning appliances are designed for use as a supplemental heater. They are not intended for  
continuous use as a primary heat source.  
AVERTISSEMENT:Assurez-vousdebiensuivrelesinstruc-  
tionsdonnées danscettenoticepourréduireauminimum  
le risque d’incendie ou d’explosion ou pour éviter tout  
dommage matériel, toute blessure ou la mort.  
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.  
POURVOTRESÉCURITÉ: Nepasentreposerniutiliserd'essence  
ni d'autres vapeurs ou liquides inflammables à proximité de  
cet appareil ou de tout autre appareil.  
POUR VOTRE SÉCURITÉ: Que faire si vous sentez une odeur  
de gaz:  
• Ne pas tenter d'allumer d'appareil.  
• Ne touchez à aucun interrupteur.  
• Ne pas vous servir des téléphones se trouvant dans le bâti-  
ment  
• Appelez immédiatement votre fournisseur de gaz depuis un  
voisin. Suivez les instructions du fournisseur.  
• Si vous ne pouvez rejoindre le fournisseur de gaz, appelez  
le service des incendies.  
L'installation et l'entretien doivent être assurés par un  
installateur ou un service d'entretien qualifié ou par le  
fournisseur de gaz.  
FOR YOUR SAFETY  
Do not store or use gasoline or other flammable  
vapors or liquids in the vicinity of this or any other  
appliance.  
WHAT TO DO IF YOU SMELL GAS:  
• DO NOT light any appliance.  
• DO NOT touch any electrical switches.  
• DO NOT use any phone in your building.  
• Immediately call your gas supplier from a  
neighbor’s phone. Follow your gas supplier's  
instructions.  
• If your gas supplier cannot be reached, call  
the fire department.  
Installationandservicemustbeperformedbyaquali-  
fied installer, service agency or the gas supplier.  
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Cautions & safety  
FOR YOUR SAFETY do not install or operate your Fire-  
Your Lennox™ gas insert must be equipped for the  
proper fuel type & altitude at which it will be operated.  
Any operation outside the parameters outlined in this  
manual may result in a hazardous condition & will void  
thewarranty.Pleasecarefullyreadthesectionspertain-  
ing to these subjects and/or be sure your appliance is  
properly equipped.  
Do not use this insert if any part has been under water.  
Immediatelycallaqualifiedservicetechniciantoinspect  
theappliance&toreplaceanypartofthecontrolsystem  
& any gas control which has been under water.  
Due to high temperatures, the insert should be located  
out of traffic areas & away from furniture & draper-  
ies.  
star™ gas insert without first reading & understanding  
this manual. Any installation or operation of the appli-  
ance deviating from that which is stated in this manual  
WILL void the warranty & may be hazardous.  
INSTALLATION & REPAIR SHOULD ONLY BE DONE BY  
A QUALIFIED SERVICE TECHNICIAN. DO NOT ATTEMPT  
TO SERVICE THE APPLIANCE YOURSELF.  
The insert should be inspected & cleaned before use  
& at least annually by a qualified service technician.  
More frequent cleaning may be required due to exces-  
sive lint from bedding material, carpeting, etc.  
It is imperative that control compartments, burners, &  
circulating air passageways of the room heater be kept  
clean.  
Children & adults should be alerted to the hazards of  
high surface temperature & should stay away to avoid  
burns or clothing ignition. Young children should be  
carefullysupervisedwhentheyareinthesameroomas  
the Lennox gas insert. Clothing or any other flammable  
material should not be placed on or near the insert.  
Never use solid fuels such as wood, paper, cardboard,  
coal, or any flammable liquids, etc., in this appli-  
ance.  
Any grill, panel, or glass removed for service MUST be  
replaced prior to operating the insert. Do not operate  
appliance with the glass front removed, cracked or  
broken. Replacement of the glass should be done by a  
qualified service technician.  
DO NOT USE abrasive cleaner on the glass door assem-  
bly. DO NOT ATTEMPT to clean the glass door when it  
is hot.  
Gold & nickel plated surfaces must be cleaned with  
glass cleaner & a clean soft cloth before firing the first  
timeorngerprintswillremainpermanently.NEVERuse  
brass polish to clean gold or nickel, this will remove  
the plating!!!  
When opening the lower door on the face while the  
insert is burning, pull at the far left or far right vent  
openings, because the door is hot during operation.  
Lennox Hearth Products, its employees, or any of its  
representatives assume no responsibility for any dam-  
ages caused by an inoperable, inadequate, or unsafe  
condition as a result of any improper operation, service  
or installation procedures, whether direct or indirect.  
INSTALLER: THESE INSTRUCTIONS ARE TO REMAIN  
WITH THE HOME OWNER!  
Adequate clearances around the combustion chamber  
and accessibility clearances for servicing & proper  
operation must be maintained.  
Turn off the gas before servicing this appliance. It is  
recommended that a qualified service technician per-  
form an appliance check-up at the beginning of each  
heating season.  
All installations must conform with all local, state, &  
nationalcodes.Intheabsenceoflocalcodes,theinstal-  
lation must conform with National Fuel Gas Code ANSI  
Zꢀꢀꢁ.1-latest edition, also known as NFPA 54. Refer  
to the National Fuel Gas Code & local zoning & code  
authorities for details on installation requirements.  
Your Firestar gas insert must be vented to the outside  
in accordance with the latest edition of the National  
Fuel Gas Code.  
This gas insert MUST be vented directly to the outside  
& MUST NEVER be attached to a chimney serving a  
separate solid fuel burning appliance. Each gas appli-  
ance MUST USE a separate vent system. Common vent  
systems are PROHIBITED.  
This appliance uses room air for combustion. It is im-  
perative that provisions for adequate combustion and  
ventilationairbemade. ThisapplianceisNOTdesigned  
to and will not operate in a negative pressure. Contact  
your dealer if you suspect such a situation exists.  
MobilehomeinstallationsmustconformwiththeMobile  
Home Construction and Safety Standard, Title ꢀ4 CFR,  
Part ꢁꢀ80, or, when such a standard is not applicable,  
theStandardforMobileHomeInstallations,ANSIAꢀꢀ5.1  
- latest edition.  
The appliance, when installed, must be electrically  
grounded in accordance with local codes or in the  
absence of local codes, with the National Electrical  
Code, ANSI/NFPA 70 - latest edition.  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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Theinstallermustmechanicallyattachthemarkingsupplied  
with the gas fireplace insert to the inside of the firebox of the  
fireplace into which the gas fireplace insert is installed.  
Orifice Size/Altitude Adjustment  
For altitudes above 2,000 feet, the orifice should be de-rated  
by 4% for every 1,000 feet to maintain the proper ratio of  
gas to air. Improper orifice sizing may result in damage  
and unsafe conditions. Changing the orifice should only be  
done by a qualified service technician. Contact your Lennox  
Hearth Products dealer for proper orifice sizes (see Page 21  
and 24 for more information).  
IMPORTANT: When installing these appliances into a fac-  
tory built fireplace or heat-form, the air flow within and  
aroundthereplaceshallnotbealteredbytheinstallation  
of the insert (i.e. DO NOT BLOCK louvers or cooling air  
inlet or outlet ports, circulating air chambers in a steel  
fireplace liner or metal heat circulator).  
The Firestar™ Insert  
WARNING  
• Mustconformwithalllocal,state,andnationalinstallation  
codes. Intheabsenceoflocalcodes, theinstallationmust  
conformwithNationalFuelGasCodeANSIZ223.1-latest  
edition, also known as NFPA 54. Refer to the National  
Fuel Gas Code and local zoning and code authorities for  
details on installation requirements.  
THIS FIREPLACE HAS BEEN ALTERED TO  
ACCOMMODATE A FIREPLACE INSERT AND  
SHOULD BE INSPECTED BY A QUALIFIED  
PERSON PRIOR TO RE-USE AS A  
CONVENTIONAL FIREPLACE.  
• Must conform with the Manufactured Home Construc-  
tion and Safety Standard, Title 24 CFR, Part 3280, or  
when such a standard is not applicable, the Standard for  
Manufactured Home Installations, ANSI A225.1 - latest  
edition for manufactured (mobile) home installations.  
• Must be vented directly to the outside in accordance with  
the latest edition of the National Fuel Gas Code and must  
never be attached to a chimney serving a separate solid  
fuel burning appliance.  
Codes & Approvals  
CertifiCation  
Gas appliances must be tested and certified by a nation-  
ally recognized testing and certification laboratory to ANSI  
(American National Standard Institute) gas appliance safety  
standards.  
• Uses room air for combustion. It is imperative that provi-  
sionsforadequatecombustionandventilationairbemade.  
This appliance is NOT designed to and will not operate in  
a negative pressure. Contact your dealer if you suspect  
such a situation exists.  
This insert has been tested and certified by OMNI -Test  
Laboratories to ANSI Z21.88-2005 Standard for Vented  
Gas Fireplace Heaters and UL 307B Gas Burning Heating  
Appliances for Manufactured (Mobile) Homes.  
• Has been certified for use with either natural gas or pro-  
pane.  
It has met all necessary ANSI Standards and is fully certified  
for installation in any community. If there are any questions  
or if you need further substantiation either write to or call  
your Lennox Hearth Products dealer. If you have further  
questions, please contact Lennox Hearth Products.  
• Is not for use with solid fuels.  
• Is approved for sitting rooms and/or bedrooms.  
new york City, new york (mea)  
Fireplace Requirements  
Installation of these fireplaces are approved for installa-  
tion in New York City in the US state of New York (MEA#:  
138-07-E).  
These heaters are designed to be installed into an existing  
masonry fireplace (built to UBC 37 standards) or factory  
built solid fuel, wood burning fireplace (listed to UL 127  
standards) only. All exhaust gases must be vented outside  
the structure. Combustion air is drawn from outside the  
structure. When installing in a factory built fireplace, the  
fireplace grate must be removed and the damper must be  
removed or secured open.  
Commonwealth of massaChusetts requirements  
Installation of these fireplaces are approved for installation  
in the US state of Massachusetts if the following additional  
requirements are met -  
• Installation and repair must be done by a plumber or gas  
fitter licensed in the Commonwealth of Massachusetts.  
• The flexible gas line connector used shall not exceed 36  
inches (92 centimeters) in length.  
• The individual manual shut-off must be a T-handle type  
valve.  
If the factory-built fireplace has no gas access hole(s) pro-  
vided, an access hole of 1-1/2 inches (38 mm) or less may  
be drilled through the lower sides or bottom of the firebox  
inaproperworkmanshiplikemanner.Thisaccessholemust  
be plugged with a non-combustible insulation after the gas  
supply line has been installed.  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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paCkaging list  
Pre-Installation  
features  
To install a Firestar insert, an insert body, and surround  
(flange) kit are required.  
Installation Options  
Insert Body Packaging List  
Residential - Vented Vertical Only  
Manufactured (Mobile) Home  
Natural Gas Or Propane (LP)  
Bedrooms  
1 Insert Body with Burner Cassette and trivet  
1 Set of Refractory Brick Panels - 3 pieces (H5866)  
1 Log Set (H5860)  
1 Lower front 2” filler panel  
1 Fasteners: 6 slotted 1/4" truss screws  
4 speed nuts  
Optional Wall-mounted Or Remote Thermostat  
Electrical  
6 spring clips  
4-3/8” x 3” leveling bolts  
The fan motor requires 120 Volts AC for operation. The  
fireplace is not dependent on the fan or an outside electrical  
supply to operate.  
2 socket head screws  
1 Installation and Operation Manual  
Surround Kits - One Required  
Millivolt Valve  
ꢀ9 X 41” Black Trim (7507ꢀ)  
ꢀ9 X 48” Black Trim(7507ꢁ)  
ꢁꢁ X 41” Black Trim(75074)  
ꢁꢁ X 48” Black Trim(75075)  
This insert is operated with a millivolt valve and therefore  
burns even during a power outage.  
Fuel  
Surround Kit Contents  
This insert comes from the factory equipped to burn natural  
gas at a specified elevation. The insert can be converted  
to burn LP (liquid propane) by installing a conversion kit.  
Only Lennox Hearth Products conversion kits can be used  
to convert from NG to LP or LP to NG. Contact your Lennox  
Hearth Products dealer for details.  
1 Top Surround  
2 Side Surrounds  
3 Black Trim Pieces  
2 Elbowed Trim Fasteners  
RATINGS  
Firestar™ (GC3)  
NATURAL GAS  
39,000/27,500  
1.7 - 3.5  
LP GAS  
39,000/22,600  
3.5 - 10.0  
10.5 - 13.0  
31,200  
MAX/MIN INPUT BTUH 0-2,000 FT (0-610 M)  
u
MANIFOLD PRESSURE (IN. WC)  
MIN./MAX. INLET PRESSURE (IN. WC)  
5.0 - 10.5  
31,200  
MAXIMUM HEAT OUTPUT BTUS/ HOUR “STEADY STATE”  
ORIFICE (DMS) 0-2,000 FT (0-610 M)  
u
#37  
#52  
u Unit factory equipped for 0-ꢀ000 FT/0-610 M  
5
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insert dimensions  
minimum fireplaCe Cavity  
See Figures 1, 2 and 3 showing insert dimensions and mini-  
mum fireplace firebox dimensions to aid you in determining  
proper fit into existing fireplace.  
23-3/4”  
11-3/8”  
A
B
4”  
9-7/8”  
C
D
Figure ꢁ  
minimum fireplaCe opening required  
20-3/8”  
20”  
19”  
A = 29-3/4” Front Opening  
B = 19” Height  
C = 19” Rear Width  
D = 15-1/4” Fireplace Depth  
*2”  
7-3/8”  
13-3/4”  
CAUTIONS  
10-1/2”  
24-3/4”  
• The fireplace in which this gas insert is to be  
installed must be thoroughly cleaned if it has  
been used to burn wood or synthetic logs. Have  
the chimney and all inside surfaces of the fire-  
place brushed and vacuumed so that no soot,  
embers, or loose combustion deposits can be  
drawnintotheheatcirculationblowerandblown  
into the living area.  
* Equipped from the factory with a 2” filler. Contact your  
dealer for additional information.  
Figure 1  
41”  
26-3/4”  
26-1/4”  
• Ifanyportionofthechimneysystemshowssigns  
of structural or mechanical weaknesses, such  
as: cracks, leaky joints, corroded or warped  
surfaces, the faulty portion must be repaired  
or replaced prior to installing this appliance.  
• The factory built firebox must accept the insert  
withoutmodificationotherthanremovingbolted  
or screwed together pieces such as baffles /  
smoke shelf / deflectors, ash lips, glass door,  
screen or door tracks, log grates, refractory or  
masonry lining and damper assemblies. Any  
fireplacecomponent,whichisremoved,mustbe  
retainedsotheycanbereinstalledtorestorethe  
fireplace to its original operating condition. The  
removal of any part must not alter the integrity  
oftheoutershellofthepre-engineeredreplace  
cabinet in any way. Any parts removed must be  
replaceable. If any components are removed  
from (or altered) from the existing fireplace,  
a Warning Label (see Page 4) must be affixed  
inside the fireplace firebox, so that it shall be  
visibleuponremovalofthereplaceinsert. Note:  
RTV high temperature silicone is an approved  
adhesive to affix the label.  
13-3/4”  
11-3/8”  
7-3/8”  
2-1/8”  
9-7/8”  
33-1/2”  
Figure ꢀ  
Insert Dimensions  
Width of insert behind Surround Panels  
ꢀ6-ꢁ/4”  
18-7/8”  
1ꢁ-5/8”  
11-ꢁ/8”  
Rear height  
Insert depth into fireplace  
Flue center line from back of surround with  
standard draft hood  
Flue collar diameter (OD)  
ꢁ-15/16”  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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minimum ClearanCes to Combustibles  
ClearanCes  
The letters below, C through H, correspond to Figure 4  
showing minimum clearances required from the appliance  
to combustibles and the minimum projection of the hearth  
extension.  
Mantel  
Trim  
C = 6.5” to Side Facing (3/4” or less)  
D = 11” to Side Wall  
E = 24” to Mantel** (more than 3/4”)  
F = 14.5” to Top Facing (maximum thickness 3/4”)  
E**  
F
C
hearth proteCtion  
H
D
G
G = Minimum Hearth Protection from Front of Insert*  
H = Vertical Distance from Insert Bottom to Combustible  
Material.  
Hearth / Floor Protection  
23”  
0”  
20”  
2”  
17”  
4”  
0”  
6”  
G
H
Figure 4  
(*Insert bottom is the metal lip below the lower gold trim bar).  
**The minimum distance from the top of the insert to a  
combustible may be reduced to 16” with a mantel shield.  
The shield should be made from 18-gage or thicker sheet  
metal, 7” by 33”. The shield must be centered over the  
insert and spaced one inch below the mantel. The shield  
can be fastened to and spaced from the mantel using four  
to six screws.  
Note: Hearth protection to be min. ꢁ/8” (10mm) thick non-  
combustible or equivalent, with a k factor of .84.  
insert leveling  
The FireStar™ insert comes with four 3/8”X 3” leveling bolts  
(two for use at the rear and two at the front of the insert).  
The two at the rear can be used to raise the back of the insert  
resting on the fireplace hearth. The two at the front can be  
used to adjust the front of the insert on the hearth extension.  
To install the bolts a 3/8” nut should be threaded onto the  
bolt, followed by a 3/8” flat washer. The bolt should then  
be installed from the under side of the insert into the captive  
nut in the bottom of the insert. When the bolt is adjusted  
to the proper height the nut previously threaded onto the  
bolt can be snugged up to the insert bottom.  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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Installation  
Chimney Cap  
Storm Collar  
insert venting  
Refer to Figure 6 which shows a typical installation of this ap-  
pliance into an existing solid-fuel fireplace.  
Chimney - Use With  
B-vent Chimney Or  
Single Wall Gas Vent  
Flex Chimney Liner  
Listed To UL 1777 Or  
ULC S6ꢁ5.  
WARNING: This appliance is equipped with a safety control sys-  
tem designed to protect against improper venting of combustion  
products. Operation of this heater when not connected to a prop-  
erly installed and maintained venting system or tampering with  
the blocked vent shut-off system can result in carbon monoxide  
(CO) poisoning and possible death.  
Insert must be vented to the outside in accordance with the current  
edition of the National Fuel Gas Code ANSI-Z223.1-latest edition,  
also known as NFPA 54. The insert must not be connected to a  
chimney flue serving a separate solid fuel burning appliance.  
This gas insert requires a 4” diameter B-vent or listed flex alu-  
minum or stainless chimney liner extending the entire length  
of the chimney to ensure proper operation. The vent should  
terminate with a chimney cap or rain cap. Chimney should be  
sealed around cap to prevent air and rain from entering chimney.  
Adhere to vent manufacturer's instructions for installation and  
vent termination.  
A minimum flue height of 1ꢀ feet is recommended.  
Figure 6  
The insert must be installed so the draft hood is in the same  
atmospheric pressure zone as the combustion air inlet to the  
appliance.  
WARNING  
Do not substitute the heat-rated flex liner (UL1777 or ULC  
S6ꢁ5) for the exhaust with any other type liner or a fire  
may result causing property damage, personal injury or  
loss of life.  
flue Collar ConneCtion  
This insert has a detachable flue  
collar to ease installation. To detach  
flue collar lift removable vent (trivet)  
from top of insert, unscrew draft tube  
retaining screw (see Figure 5) and  
slide draft tube and flue collar to the  
rear. Attach flue collar (with 3 sheet  
metal screws or a B-vent connector)  
to vent pipe previously installed in  
chimney. As the insert is pushed into  
fireplace guide draft tube and flue col-  
lar into guide brackets until draft tube  
retaining screw can be reinstalled in  
The following vent liner kits are available from Lennox Hearth  
Products (see Figure 7 and table below).  
Draft Tube  
Retaining  
Screw  
its original hole.  
Figure 7  
VENT KITS  
Cat. #  
H0906  
H0907  
Model  
Description  
Figure 5  
VKBVIꢀ5  
VKBVIꢁ5  
BVI, 4" Dia. x ꢀ5’ Length  
BVI, 4" Dia. x ꢁ5’ Length  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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zero ClearanCe fireplaCe installation  
log installation instruCtions  
CAUTION: If the logs are not properly installed, your insert  
will not function properly.  
This insert may be installed in a masonry or factory built/zero  
clearance (ZC) fireplace. When installing in a ZC fireplace,  
the ZC grate must be removed and the ZC damper must be  
removed or secured open. The ZC doors, screen, refractory  
or masonry lining, baffles, and smoke shelf may be removed,  
if necessary, to install the gas insert. However, do not cut  
or alter the fireplace components. The removal of any parts  
to facilitate installation must not alter the integrity of the  
inner or outer shells of the fireplace cabinet. See Fireplace  
Requirments on page 4.  
Part list: Rear log, Right Front log, Left Front log, and  
Top Twig  
1. Remove the logs from the box and carefully unwrap them.  
The logs are fragile, so handle them with care.  
2. Place the rear log with the charred surface forward, on  
the two rear locating pins (see Figure 9).  
3. Place the left front log, with the charred surface forward,  
(see Figure 10) on the two left front locating pins. Next  
place the right front log, with the charred surface forward,  
on the two right front locating pins.  
glass door removal  
See page 17 for Glass Door Removal Instructions.  
Continued on Page 10...  
briCk liner installation  
Rear Log  
HANDLE THE BRICK PANELS WITH CARE (SEE FIGURE 8)  
AS THEY ARE FRAGILE. DO NOT FORCE THE PANELS INTO  
THE FIREBOX AS THEY WILL BREAK IF FORCED.  
Figure 9  
1. Open and remove glass door, see “Front Door Remov-  
al”  
2. The longest panel goes in the rear of the firebox. Tilt the  
top of the panel forward, insert the bottom of the panel  
in the brick panel retainer and push the panel to the up-  
right position.  
3. Install the side panels by sliding the top of the panel into  
the top side brick retainer and then dropping the bottom  
of the panel into the bottom retainer. The rounded edge  
on the side brick panels goes toward the front.  
Left Front  
Log  
Right Front  
Log  
3-Piece Brick Panel Set  
Figure 8  
Figure 10  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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log installation Continued (gC3)  
surround installation  
Install per the following instructions (refer to Figure 1ꢁ).  
The FireStar™ insert flanges are made of heavy 12 gage  
steel for durability and, if desirable, for the ease of making  
an inside fit in the fireplace. See “Packaging List” for sizes  
available. The side flanges extend 2” below the bottom of  
the insert and align with the 2” lower filler panel. In those  
few instances when the elevation of the hearth necessitates,  
2” can be cut from the bottom of the side flanges and the  
insert placed directly on the hearth- not using the leveling  
bolts or filler panel.  
4. Position the top twig, with the charred end forward, on  
the pin in the top of the rear log and the pin in the top of  
the right front log (see Figure 11).  
5. Place the volcanic stone one high in front of the front  
burner tube (see Figure 12). Take care not to cover all the  
burners ports. Any extra volcanic stone may be placed  
at the ends of the front logs, off the burner. Place small  
pinches of rockwool (embers) on top of the volcanic  
stone.  
1. Remove the speed nuts from the parts bag and install  
(with the flat surface forward) on the six holes in the  
flange brackets (three on each side of the insert). A flat  
bladed screwdriver may help in installing the nuts.  
2. Install all flanges and trim with the insert positioned in the  
fireplace but a few inches in front of its final location.  
3. Open side doors and install the side flanges by lining up the  
holes in the tabs on the side flanges in front of the holes on  
the flange brackets. (Note that the larger tab on side flange  
goes at the bottom and the front leveling bolts need to be  
raised to at least two inches to accommodate the length of  
the side flanges). Next insert two slotted 1/4” truss screws  
for each side flange and secure loosely.  
Top Twig  
4. Fasten top flange with the remaining two truss screws.  
Tighten all six truss screws after shifting flanges to  
eliminate space between side and top flanges.  
5. Install two spring clips approximately five inches from each  
end of each of the three gold trim pieces. The spring clips  
shouldbeinstalledinthechannelofthetrimwiththecurved  
end to the front toward the rounded surface of the trim.  
6. Place the longest trim piece with the rounded surface  
out along the edge of the top flange with the spring clips  
slightly behind the flange. Pull the trim forward, com-  
pressing the spring clips, and slide the trim down onto  
the flange.  
7. Insert the elbowed retainer in the mitred end of the side  
trimpiecesandfastenwithatscrewdriver. Inserttheother  
end of the retainer in the end of the already installed top  
flange and slide side trim onto the edge of the side flange  
compressing spring clips in the process. Repeat the same  
steps for the other side trim. Fasten the elbowed retainer  
securely in the top flange making a nice mitred corner.  
Figure 11  
Note: The pilot flame can be  
viewed through the burned hole  
in the right front log.  
Top Flange Mounting Holes  
Volcanic Stone  
Figure 1ꢀ  
Figure 1ꢁ  
Side Flange Mounting Holes  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
10  
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If the pressure is not sufficient, make sure the gas supply line  
is large enough, the supply regulator is properly adjusted, and  
the total gas load for the residence does not exceed the amount  
supplied.  
lower front 2” filler panel  
The FireStar™ insert comes with a 2” panel to fill the space be-  
tween the insert bottom and the hearth extension. If the hearth  
elevations necessitate, the insert may be installed directly on the  
hearth without the leveling bolts or filler panel. To install the panel,  
insert the four tabs on the top of the panel into the corresponding  
slots in the insert bottom. Open the insert side doors, remove the  
two socket head screws from the hardware bag and install them  
(usinga5/32hexwrench)throughtheinsertbottomintotheller  
panel. A tall adjustable filler panel is also available.  
The appliance and its individual shut off valve must be  
disconnected from the gas supply piping system during any  
pressure testing of that system at test pressures in excess of  
1/ꢀ psig.  
The appliance must be isolated from the gas supply piping  
system by closing its individual manual shut-off valve during  
any pressure testing of the gas supply piping system at test  
pressures equal to or less than 1/ꢀ psig. Check with your gas  
supplier or plumber.  
gas line installation  
After leveling, position the insert in the fireplace, holding it about  
six inches out from its final location.  
Fuel  
Type  
Inlet Pressure  
Manifold Pressure  
Desired Minimum Maximum  
On Hi  
Fire  
On Lo  
Fire  
Caution: Specific Hearth Requirements apply (see Clearances  
and Specifications). The Firestar gas insert must be connected  
to the gas line in accordance with local codes and / or the  
National Fuel Gas Code, Zꢀꢀꢁ.1-latest edition, also known as  
NFPA 54. Included in the manual package is an 8" gas nipple.  
Locate the threaded gas inlet on the lower left of the insert.  
Thread the 8" gas nipple into the inlet with a teflon sealer or  
equivalent. Attach the gas supply line to this hard pipe. The  
hard pipe can receive a ꢁ/8” inch female iron pipe coupling, or a  
shut off valve. After connecting the gas line, all joints in the line  
and connections at the valve should be checked for leaks.  
Natural 7" WC  
Gas  
5" WC  
10.5" WC ꢁ.5" WC  
1.7" WC  
LP Gas 11" WC 10.5" WC 1ꢁ" WC  
Table 1  
10.0" WC 5.4” WC  
gas supply line sizing  
The proper gas line diameter must be selected to run from the  
supply regulator to the insert. Refer to the Table 2 for proper gas  
pipe diameters.  
gas pressure requirements  
A MAJOR CAUSE OF OPERATING PROBLEMS WITH GAS  
APPLIANCES IS IMPROPER GAS PRESSURE!  
NOTE: Someareasallowcoppertubing-checkwithlocalapproval  
agencies and codes.  
The most important item to check during the initial  
installation and the first thing to check when operating  
problems occur is gas pressure! This appliance will not  
function properly unless the required gas pressure is  
supplied. See Table 1 for gas pressure requirements.  
Two pressure taps are provided on the insert's valve to check  
gas pressures. The taps are located below the on/off/pilot knob  
(see Figure 14). The left tap is the inlet (supply) pressure side.  
To check inlet pressure (with the insert burning), insert a small  
phillips screwdriver into the tap and turn a half turn counter-  
clockwise. Cover the tap with the line from a manometer and  
check the pressure. Close tap gently but securely after completing  
the check. The manifold (outlet) tap is to the right of the inlet tap.  
To check manifold pressure (with the insert burning at the high  
burn setting) insert a small  
COPPER TUBING NOT ALLOWED IN MASSACHUSETTS IN  
NATURAL GAS INSTALLATIONS, NEVER USE GALVANIZED OR  
PLASTIC PIPES.  
Pipe Length  
(Feet from Supply  
Regulator)  
Schedule 40 Pipe  
Inside Diameter  
(Black Pipe)  
Tubing, Type L Outside Diam-  
eter (Copper)  
(Do Not Use Copper in Massachusetts  
with Natural Gas)  
L.P.  
Natural Gas  
L.P.  
Natural Gas  
1
3
1
3
/
2
"
/
8
"
/
2
"
/
8"  
0-10  
(1.3 cm)  
(1.0 cm)  
(1.3 cm)  
(1.0 cm)  
1
1
5
1
/
2"  
/
2
"
/
8
"
/
2"  
10-40  
(1.3 cm)  
(1.3 cm)  
(1.6 cm)  
(1.3 cm)  
phillips screwdriver into  
the tap and turn a half turn  
counter-clockwise. Cover  
the tap with the line from  
the manometer and check  
the pressure. Again close  
the tap gently but securely  
after completing the check.  
Checkthetapsforgasleaks  
withagasleaktestsolution  
(retighten if necessary).  
Inlet Elbow  
1
1
3
1
/
2
"
/
2
"
/
4
"
/
2"  
40-100  
(1.3 cm)  
(1.3 cm)  
(2.0 cm)  
(1.3 cm)  
3
1
7
3
/
4
"
/
2
"
/
8
"
/
4"  
Inlet  
Off/On/Pilot  
Manifold  
Pressure Tap  
Flame Height  
Adjustment  
100-150  
150-200  
(2.0 cm)  
(1.3 cm)  
(2.3 cm)  
(2.0 cm)  
Pressure  
Tap  
3
1
7
3
/
4
"
/
2
"
/
8
"
/
4"  
(2.0 cm)  
(1.3 cm)  
(2.3 cm)  
(2.0 cm)  
Outlet  
Orifice  
Table ꢀ  
Figure 14  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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propane (lp) and natural gas supplies  
Firebox  
Your Firestar™ gas insert is equipped from the factory for  
use with natural gas only as specified on the Safety / Listing  
label attached to the appliance. This appliance can only be  
operated using propane gas (LP) if a certified fuel conver-  
sion kit provided by Lennox Hearth Products is installed by  
a qualified service technician.  
Air Control Panel  
Alsochecktheorificesizeonthelabelattachedtoyourcontrol  
panel. It must be the correct size for the fuel and altitude.  
Do not run propane tank dry. Running the tank dry may  
cause a hazardous condition due to pressure drop in  
empty tank.  
Remove Allen-Head Screw  
Figure 15a  
Solid fuel is NOT to be used with this unit.  
Lift Out Air Control Panel  
air shutter adjustment  
The main burner has an adjustable air shutter located at  
the end of the burner as it inserts over the orifice. It is  
located behind the right side door and beneath the control  
valve. The shutter adjustment has been set at the factory  
to ensure proper, safe combustion and flame pattern. Only  
a qualified gas technician should adjust the air shutter as  
an incorrect adjustment could cause a hazardous condition.  
Closing the air shutter will cause the flames to take on a  
yellow color. Closing it too far will cause improper burning  
and the flames will turn orange and sooty. Opening the air  
shutter will cause the flames to burn cleaner; becoming  
transparent and bluish.  
Figure 15b  
Remove Allen-Head Screw  
Burner Tube Assembly  
Caution: The air shutter should never be closed to such  
an extent to create sooting on the viewing glass, logs or  
heat exchanger. If soot begins to form after burning, the  
air shutter should be opened gradually until the sooting  
conditionstops. Opentheshutterasmallamountatatime  
untilthesootingceases. SeeFlameColorandBehavior”  
and “Maintenance”, proper pilot flame.  
Figure 15c  
1. Remove glass door (see Glass Door Removal on page  
17). Carefully remove the log set and set aside.  
2. Using a 5/32” allen wrench, remove the allen-head screw  
on the left side of the air control panel as shown in Figure  
15a, then lift out air control panel as shown in Figure  
15b.  
Lift Out Burner Tube Assembly  
3. Using a 5/32” allen wrench, remove the screw which  
secures burner tube assembly as shown in Figure 15c.  
Then lift out burner tube assembly as shown in Figure  
15d.  
4. Usingaphillipsscrewdriver,loosentheairshuttersetscrew  
just enough so air shutter can be rotated by hand (read  
note below). See Figures 15e and 15f.  
Figure 15d  
5. Reinstall components by reversing steps 1 - 4.  
6. Locate the air shutter, behind the right side access door  
(below valve), then adjust the air shutter gap until the  
proper flame characteristics are achieved.  
Setscrew  
Note: The setscrew for the air shutter is secured tightly  
from the factory so that it does not rotate from the factory  
settingduringshipping.Onceyouloosenthesetscrewjust  
enough so that it can be rotated by hand, then reinstall the  
burner tube, you will be able to access and adjust the air  
shutter from behind the right side panel (below valve).  
Air Shutter  
Air Shutter  
Figure 15e  
Figure 15e  
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C. Use only your hand to push in or turn the gas control  
knob. Never use any tool. If the knob will not push in or  
turn by hand, don't try to repair it, call a qualified service  
technician. Force or attempted repair may result in a fire  
or explosion.  
D.DONOTusethisapplianceifanyparthasbeenunderwater.  
Immediately call a qualified service technician to inspect  
theapplianceandtoreplaceanypartofthecontrolsystem  
and any gas control which has been under water.  
Operating Instructions  
pre-lighting CheCklist  
Be sure to check these items before the initial lighting of  
the insert:  
- All packaging materials are removed from the firebox;  
brick panels and logs are installed.  
- The insert gas label must correspond to the gas supply  
available, that is “natural gas” for natural gas; "LP gas"  
for LP gas.  
- Be sure the gas pressure has been carefully checked (see  
Gas Pressure Requirements).  
OPERATING INSTRUCTIONS  
(Refer to controls shown in Figure 16)  
- Fingerprints or other marks are cleaned (while the insert  
is cool) from any gold or nickel surfaces with denatured  
alcohol and a soft cloth. Marks left on these surfaces  
may become etched into the finish if not removed prior  
to burning the unit.  
CAUTION: Your Lennox™ gas INSERT MUST ALWAYS BE  
OPERATED WITH GLASS IN PLACE.  
STOP!! Read the safety information above before pro-  
ceeding.  
1. Openthelowerdoor. Makesuregassupplyshut-offcocks  
are open and ON/OFF rocker switch is "OFF." If equipped  
with a thermostat, set it to the lowest setting.  
2. Turn off all electrical power to the appliance.  
- Check all gas fittings for leaks.  
- Remove all combustible materials from the area in front  
of the insert and ensure the vented areas of the insert face  
are unobstructed.  
- Check to ensure all clearances to combustibles are met-  
see page 7.  
3. Push in gas cock dial slightly and turn clockwise  
"OFF."  
to  
- Make sure the glass door is in place and properly sealed  
before burning the appliance  
NOTE: Dial cannot be turned from "PILOT" to "OFF" unless  
dial is pushed in slightly. Do not force.  
4. Wait five minutes to clear out any gas. Then smell for gas,  
including near the floor. If you smell gas, STOP! Follow  
"B" above. If you don't smell gas continue.  
5. Locate the pilot by looking over the top of the left front  
log. A blue flame will be seen when the pilot is lit.  
- Ventilate the house to clear initial paint curing odors, see  
page 15.  
Lighting Instructions  
The following is a copy of the operating and lighting instruc-  
tions found with each insert:  
6. Turn the gas control knob counter-clockwise  
the "PILOT" position.  
to  
FOR YOUR SAFETY READ BEFORE OPERATING  
7. Push the knob all the way in and hold in that position.  
Immediately light the pilot by pressing the igniter button  
several times until pilot is lit. Continue to hold the knob in  
forabout30secondsafterthepilotislit.Releaseknoband  
it will pop back out. Pilot should remain lit. If it goes out,  
repeat steps 4-8 holding knob in an additional 15 seconds  
after pilot is lit. If knob does not pop out when released,  
stop and immediately call your service technician or gas  
supplier. If the pilot will not stay lit after several tries,  
turn the gas control knob to "OFF" and call your service  
technician or your gas supplier.  
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS  
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING  
PROPERTY DAMAGE, INJURY, OR LOSS OF LIFE.  
CAUTION: HOT WHILE IN OPERATION. DO NOT TOUCH. KEEP  
CHILDREN, FURNITURE, GASOLINE, AND OTHER LIQUIDS  
WITH FLAMMABLE VAPORS AWAY. NEVER OPERATE UNIT  
WITH GLASS OFF OR ATTEMPT TO REMOVE THE GLASS  
WHILE HOT.  
A.This appliance is equipped with a piezo ignition device  
to light the pilot. When lighting the pilot, follow these  
instructions exactly.  
B.BEFORE LIGHTING, smell around the appliance area for  
gas. Be sure to smell next to the floor, because some gas  
is heavier than air and will settle on the floor.  
8. After pilot is lit, turn gas control knob counter-clockwise  
to "ON." Knob can only be turned to "ON" if the  
knob has popped out.  
9. To turn burner on, turn "ON/OFF" rocker switch to "ON"  
or set the thermostat to the desired temperature above  
room temperature.  
WHAT TO DO IF YOU SMELL GAS:  
10.Adjust the flame height (and heat output) by turning the  
DO NOT try to light the appliance.  
DO NOT touch any electric switch,  
DO NOT use any phone in the building. Immediately call  
your gas supplier from a neighbor's phone. Follow the gas  
supplier'sinstructions.Ifyoucannotreachyourgassupplier,  
call the fire department.  
flame height knob clockwise  
for full flame and  
for reduced flame.  
counter-clockwise  
11.Turn on the electric power to the appliance and set the  
blower to the desired air flow after it turns on when the  
appliance reaches operating temperature.  
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TO TURN OFF GAS TO APPLIANCE  
flame Color & behavior  
Your Firestar™ gas insert is designed for maximum heating  
efficiency. Therefore, upon lighting of the main burner the  
flames will be semi-transparent or “bluish.” After 10-20  
minutes of operation the logs will heat up and the flames  
will become a yellow/orange color.  
(Refer to controls shown in Figure 16)  
1. Turn off the "ON/OFF" rocker switch and/or thermostat (if  
installed) to its lowest setting.  
2. Turn off electric power to the appliance if service is to be  
performed.  
3. Push in gas control knob slightly and turn clockwise  
to "OFF." Do not force.  
Adjusting the insert to cause the flames to turn orange  
sooner may result in poor combustion, sooting, and a  
hazardous situation. See Figure 17 showing proper flame  
appearance.  
This appliance needs fresh air for safe operation and  
must be installed so there are provisions for adequate  
combustion and ventilation air.  
Burner Flame Appearance  
WARNING: Improperinstallation,adjustment,alteration,  
service,ormaintenancecancauseinjuryorpropertydam-  
age. For assistance or additional information, consult a  
qualified installer, service agency, or your gas supplier.  
Soot above  
Flame Tip  
Soot at  
No Soot at  
Flame Tip  
Flame Tip  
Dark Orange  
Flame  
Semi-Transparent  
Yellow Flame  
Ports on Pan  
Burner Assembly  
Operation of this appliance when not connected to a prop-  
erly installed and maintained venting system can result in  
carbon monoxide (CO) poisoning and possible death.  
No Blue Flame  
Center  
Blue Flame  
Center  
PROPERLY  
BURNING FLAME  
IMPROPERLY  
BURNING FLAME  
SHUTDOWN PROCEDURE  
Figure 17  
To turn off the burner, turn the rocker switch to "OFF" or  
adjust the thermostat (if installed) to a setting below room  
temperature. The pilot will remain lit for future burner igni-  
tion. For complete shutdown, see "TO TURN OFF GAS TO  
APPLIANCE" above.  
replaCing burner orifiCes  
To change orifices, first remove the cassette (see Fuel Con-  
version and Cassette Installation on page 19). Then unscrew  
orifice using an 3/4” open end wrench, discard the old orifice  
and reinstall the new orifice.  
REDUCING THE ORIFICE SIZE FOR HIGHER ALTITUDES  
MAINTAINS THE PROPER BTU INPUT TO AIR RATIO. TOO  
LARGE AN ORIFICE WILL RESULT IN HIGHER BTU INPUTS  
THAN THE DESIGN ALLOWS, MAY RESULT IN AN UNSAFE  
CONDITION AND MAY VOID YOUR WARRANTY.  
Robertshaw  
Gas Control  
Gas Valve  
Knob Off/On/Pilot  
Flame Height  
Control Knob  
(Hi/Lo)  
For altitudes above 2,000 ft. (610M) the appliance should be  
derated by four (4%) percent every 1,000 ft. (305M).  
To operate safely, your Firestar gas insert must have the  
proper burner orifice size determined by the altitude at  
which it will be operated and other variables such as pres-  
sure and valve tolerances. If you have reason to believe  
your insert’s orifice size may be incorrect for your altitude,  
have it checked and remedied (if necessary) by a qualified  
service technician.  
Millivolt Pilot  
ON/OFFSwitch  
Gas Pilot Hood  
ꢁ/8” to  
1/ꢀ”  
PiezoIgniter  
Thermopile  
Igniter  
Figure 16  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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paint Curing  
“on-off” switCh and thermostat  
Your gas insert comes equipped with an “ON-OFF” rocker  
switch used to turn the burner on and off while the pilot is  
on. The switch is located behind the right side door to the  
right of the control valve. This switch can be relocated to  
the hole provided in the top surround panel by pulling the  
two connectors off of the spades on the back of the switch.  
Then unscrew the plastic nut on the back side of the switch  
and pull the switch forward through the hole. Cut the wire  
tie holding the switch wire and feed the wire behind the side  
flange up to the switch hole in the top flange. Care must be  
taken to ensure the wire is kept away from the heat of the  
firebox. Reinsert the switch in the hole in the flange, tighten  
the retaining nut, and push the wire connectors back on the  
spades. Thespadesmayneedtobecarefullybentdownward  
to provide clearance between the switch and the fireplace  
facing material.  
This insert has been painted with Stovebright high tem-  
perature metallic stove paint. It leaves the factory dry to  
the touch, but finishes curing as the insert is used. Fire the  
insert four successive times for ten minutes each time with  
a five minute cool down between each firing. Ventilate the  
house during these first firings as the paint gives off car-  
bon dioxide and unpleasant odors. It is recommended that  
persons sensitive to an imbalance in the indoor air quality  
avoid the insert during the curing process.  
quiet operation  
GAS NOISE: The sound of gas flowing through the insert  
may be detectable while the unit is in operation. This is a  
normal operating sound, however if it is objectionable, it  
can be reduced by turning down the flame. Turning down  
the flame will reduce heat output.  
Amillivoltwallthermostatorremotethermostatcanbeused  
to supplement the rocker switch. The thermostat and rocker  
switch will turn the burner on and off independently of each  
other. Be sure to set the rocker switch to the off position  
when using the thermostat and set the thermostat to the  
lowest temperature when you wish to use the rocker switch  
only, otherwise one may override the other.  
BLOWERNOISE:Astheinsertheatsup,theblowerwillcome  
on to move hot air through the heat exchanger and into the  
room. Adjust the fan speed with the fan control knob to the  
sound level and air flow desired.  
blower  
Your Firestar™ gas insert comes equipped with a 150 CFM  
blower with a variable speed control and an automatic  
temperature activated On / Off snap switch.  
Follow the instructions included with the thermostat for  
wiring. Solder all connections, as good wire connections  
are critical in millivolt system. Check with your insert dealer  
for the proper length and size of the thermostat wire. Both  
factors effect the function of the thermostat.  
Operation:  
1. Plug the blower power cord into a grounded (three  
prong) outlet. This appliance is equipped with a three  
prong (grounding) plug for your protection against  
shock hazard and should be plugged directly into a  
properly grounded three - prong receptacle. Do not cut  
or remove the grounding prong from this plug.  
2. After the insert warms up, the fan will come on if the  
speed control (located at the bottom of the left side  
door) is left in the on position. The fan will not operate  
until the insert is warm.  
3. Once the fan comes on, turn the knob to the desired  
speed. No further adjustment is necessary, the fan will  
come on automatically whenever the insert is warm.  
4. If you do not wish to have the fan on, turn the knob until  
it clicks into the OFF position.  
pilot adjustment  
All pilots are burned and checked at the factory prior to  
shipment. (NOTE: If upon initial insert installation the pilot  
flame flickers or will not remain lit, most likely the pilot is  
fine but there is air in the gas line or the gas pressure is too  
low). Pilot adjustment is not normally required, but should  
it be necessary, it should be done only by a qualified service  
technician. The pilot adjustment screw is located to the  
left of the ON/OFF/PILOT control knob. With a flat bladed  
screwdriver, remove the pilot adjusting cover to access the  
pilotadjustingscrew.Adjustpilotscrewtotheproperlysized  
flame as shown in Figure 18. The flames should completely  
surround the thermopile and extend across the main burner  
ports. Be careful not to back the adjusting screw out of its  
threads. Replace the cover and check for gas leaks.  
Millivolt Pilot  
Gas Pilot Hood  
ꢁ/8” to  
1/ꢀ”  
Thermopile  
Igniter  
Figure 18  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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Donotspliceanymillivoltwires.RefertoTable3todetermine  
the proper gage of wire for the thermostat or wall switch  
connections. This table refers to the total length of the wire  
(out to the switch and back). The thermostat must be a  
millivolt type. A 24-volt furnace thermostat will not work.  
Never hook up household current, 120 Volts, to the millivolt  
system. It is not recommended to hook up any more than  
two switches to the insert (for example a rocker switch and a  
wall thermostat). Additional switches may affect the system  
resistance and increase the chance of the burner not ignit-  
ing. Follow the instructions included with the thermostat or  
remote control for wiring.  
millivolt Control system  
This insert operates on a millivolt control system. As such, no  
addition power supply is needed for the insert to operate. The  
pilot assembly contains a Thermopile, that when heated by the  
pilot flame, generates electricity (millivolts, mV=1/1000 of a volt)  
that travels to terminal #1. From this terminal it travels through  
a black wire to the Vent Safety Snap Switch. If this switch over-  
heats through a flue blockage or vent pipe disconnection it will  
open, stop the flow of mV and shut the insert off. This switch will  
automatically reset (close), when it is cooled down to normal  
operating temperature. During normal operation, it is closed  
allowing the mV to flow back to the valve, which opens so gas  
can flow through.  
The thermostat, remote control, and rocker switch will turn  
theburneronandoffindependently.Besuretosettherocker  
switch to the “OFF” position when using the thermostat or  
remote control and set the thermostat or remote control to  
the lowest temperature when you wish to use the rocker  
switch only, otherwise one may override the other. If a re-  
mote thermostat is to be used with the insert, do not place  
the receiver under the firebox.  
To check for proper operation, use a multimeter and perform the  
system checks shown in Table 4 (and refer to Figure 19).  
Millivolt and System Checks  
Check  
Test  
To  
Test  
Connect  
Meter  
Leads to  
Terminals  
Thermostat  
Connects  
Meter  
Reading  
Should Be  
Thermostat Wire  
A
B
Complete  
System  
ꢀ & ꢁ  
Closed  
Open  
100 MV  
or More  
Wire Size  
1ꢀ Gage  
14 Gage  
16 Gage  
18 Gage  
ꢀ0 Gage  
Maximum Length  
100 Feet  
64 Feet  
Thermopile  
Output  
1 & ꢀ  
Greater  
Than  
ꢁꢀ5 MV  
40 Feet  
C
System  
Resistance  
1 & ꢁ  
Closed  
80 Ohms  
ꢀ5 Feet  
16 Feet  
Table 4  
Table ꢁ  
TH  
TP  
TH  
millivolt wiring diagram  
Valve Terminals  
Valve Snap Switch  
Wire (Black) SS2  
Gas Valve  
Terminal 1  
TH/TP  
Terminal 3  
TH  
Terminal 2  
TP  
Elbow  
Inlet  
Terminal Snap Switch  
Wire (Black SS1)  
70  
Pilot Hood  
80  
60  
Piezo Igniter  
90  
50  
Vent Safety Snap  
Thermopile  
Spark Electrode  
Switch  
Off/On/Pilot  
Inlet Pressure  
Manifold  
50 60 70 80  
90  
Tap  
Pressure Tap  
Spark Electrode Wire  
(Black) connect to  
Piezo Igniter  
OPTIONAL  
Thermostat  
Flame Adjustment  
On/Off  
Switch  
Thermostat  
Wire  
Thermostat  
Wire  
(Red) TH1  
Burner Orifice  
Pilot Tube  
On/Off Switch Wire  
(Black) 001 Connect  
Terminal 1 Gas Valve  
(White) TH2  
Thermopile Wire (Brown)  
Connect to Terminals 1 & 2  
On Gas Valve  
Figure 19  
On/Off Switch Wire (Black) 002 - Connect Terminal 3 Gas Valve  
16  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
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Maintenance & Servicing  
glass door removal  
(refer to Figures ꢀ0a and ꢀ0b)  
maintenanCe CheCklist  
Caution: Do not slam or strike glass door or damage  
may occur.  
Should Only Be Performed by a Qualified Service Techni-  
cian.  
Do not remove the glass door while the insert is hot. Open  
both latches on the right and left side of the door (they  
are centered on the sides of the front door - see Figure  
ꢀ0a). With the latches released, rotate the catch part of  
each latch outward away from the front door. The door  
willpivottowardyoufromthetop(hingingfromthebottom  
as shown in Figure ꢀ0b). On the bottom of the door there  
are tabs that slide into slots on the firebox. Disengage the  
tabs on the door from the slots on the firebox by lifting up  
on the door until it stops and slide the door all the way to  
the left. You can then remove the door straight out from  
the slots. To reinstall door reverse the steps above.  
Caution: Label all wires prior to disconnection when  
servicing controls. Wiring errors can cause improper  
and dangerous operation. Verify proper operation after  
servicing.  
1.Annual inspection should be made and the following  
checks performed:  
a) With unit cool, remove glass and inspect burner for dirt,  
soot, and lint accumulations and remove if necessary.  
If excessive soot accumulation is present on burner,  
have a qualified serviceman adjust burner for proper  
combustion.  
b) Clean any deposits from inside glass with gas fireplace  
glass cleaner. NEVER attempt to remove or clean glass  
when the unit is hot.  
c) Check that chimney and its outlet are open and free from  
soot, blockage, or debris.  
d) Inspect the pilot system for proper flame. See instruc-  
tions on page 15.  
Side Door Latches  
e) Check the Millivolt system as per Table 4 on page 16.  
f) The appliance area must be kept clear and free of com-  
bustible materials, gasoline, and other flammable vapors  
and liquids.  
g) Check glass gaskets once a year. Gaskets must be tight.  
Replace if necessary.  
ꢀ.The viewing glass should be cleaned periodically (see  
Glass Maintenance).  
glass maintenanCe  
Open the top door latches by pulling them forward and up.  
Cleaning: Whencool,theglassmaybecleanedwithaclean,  
softclothandWindex.Forcleaningwhitecondensationfrom  
the interior glass, use KEL KEM gas fireplace glass cleaner  
available from your insert dealer. Use of caustic or abrasive  
cleaners may damage the glass. DO NOT operate the insert  
withbrokenglass. DONOTcleandoororglasswhenhot. DO  
NOT abuse the glass door by striking or slamming it shut.  
DO NOT use substitute materials if replacing the glass. DO  
NOT spray commercial glass cleaner with ammonia on the  
door and glass gasket as it may dissolve the gasket glue.  
Figure ꢀ0a  
Replacement: Theglassintheinsertdoorcannotbereplaced  
separately. Should the glass be damaged, the entire glass,  
gasket, and metal frame assembly must be replaced as a  
unit. Thisreplacementglassassemblyisavailablefromyour  
Lennox Hearth Products dealer. The glass is neo-ceramic  
and alternative types must not be used.  
Lower Front Door Tabs  
Door  
WARNING: Do not operate appliance with the glass panel  
removed, cracked, or broken. Do not remove glass door  
while the insert is hot. Replacement of the glass door  
should be done by a qualified service technician.  
Lift the glass door up and off the lower spring latch  
Figure ꢀ0b  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
17  
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To remove the front door open the side doors, release the  
front door latches on either side and rotate the top of the  
glass door forward and down until it stops. Once it is all  
the way open, lift it slightly, move it to the left and pull it  
away from the insert. Place door on a nonabrasive surface  
being careful not to damage door or glass. When cooled the  
exterior glass may be cleaned with a clean, soft cloth and  
windex. For cleaning white condensation from the interior  
glass use KEL KEM gas fireplace glass cleaner available  
from your insert dealer. Use of caustic or abrasive cleaners  
may damage glass.  
blower removal  
Unplugthepowersupplycordfromtheelectricaloutletprior  
toremovingtheblower.Thefancanbeaccessedthroughthe  
back wall of the firebox. Caution: Label all wires prior to  
disconnection when servicing controls. Wiring errors can  
cause improper and dangerous operation. Verify proper  
operation after servicing. See the fan-wiring diagram below  
for reference. Remove the glass door, log set, and brick pan-  
els. All of these items are fragile so handle them with care.  
Remove the two allen-head screws at the left and right front  
of the air control panel and lift the panel out. Next, remove  
the nine allen-head screws around the outside of the panel  
fastened to the back wall of the firebox. Rotate the top of  
this panel toward the front, remove the two wires connected  
to the fan, and then lift the panel with the fan attached out  
of the firebox. To reinstall the fan, repeat these steps in the  
reverse order.  
NOTE: BE CAREFUL NOT TO SPRAY COMMERCIAL GLASS  
CLEANER WITH AMMONIA ON GASKET AREA OF DOOR.  
AMMONIA WILL DISSOLVE GASKET GLUE.  
NOTE: GOLD PLATED SURFACE MUST BE CLEANED WITH  
GLASS CLEANER AND SOFT RAG BEFORE FIRING THE  
FIRSTTIMEORFINGERPRINTSANDSTAINSWILLREMAIN  
PERMANENTLY. NEVER USE BRASS POLISH TO CLEAN  
GOLD, THIS WILL REMOVE GOLD PLATING!  
eleCtriCal requirements  
This gas insert operates without an outside power source,  
howeverthefan/blowerrequiresa120Voltelectricalservice  
outlet. The blower must be electrically grounded in accor-  
dance with local codes. In the absence of local grounding  
codes, the National Electrical Code ANSI/ NFPA 70 - latest  
edition. Theblowerisequippedwithathreepronged(ground-  
ing) plug for your protection against electrical shock hazard  
and should only be plugged into a properly grounded three  
prongreceptacle. DONOTCUTORREMOVETHEGROUND-  
ING PRONG FROM THE PLUG FOR ANY REASON!  
Front door glass replacement should be completed only by  
a qualified technician.  
glass door Cleaning and repair  
Cleaning: Do not remove or clean the glass door when hot.  
Agasdoorglasscleaner(availablefromyourLennoxHearth  
Products dealer) or windex should be used with a soft cloth  
to clean the glass. Do not use an abrasive cleaner.  
See Millivolt Control Schematic (Figure 19) for information  
on thermostat and On/ Off switch.  
See Blower Wiring Diagram (Figure ꢀ1) for information on  
the wiring and electrical requirements for the blower.  
Repair: If the glass is broken in the glass door, the entire  
door (metal frame, gasket, and glass) should be replaced  
as a unit. This replacement unit is available from your Len-  
nox Hearth Products dealer. Do not use substitute parts or  
materials.  
Pan Snap Switch  
Caution: Do not operate this insert with broken glass.  
Fan Speed Control  
Speed Control  
Wire (Red)  
blower wiring diagram  
Speed Control  
Wire (Red)  
Snap Switch  
Connection  
Wire (White)  
Snap Switch Connection  
Wire (Black)  
Speed Control Connection  
Speed Control  
Connection Wire  
(White)  
Speed control Connection Wire (Black)  
Speed Control ConnectionWire (White)  
Blower  
Speed Control Connection Wire (Black)  
Main Power Cord Wire (Black)  
Ground Wire (Green)  
Main Power Cord Wire (White)  
Main Power Cord (Black)  
Figure ꢀ1  
18  
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4. Disconnect at the valve the two wire connectors from vent  
safety snap switch (the uppermost black wire on terminal 1  
and the black wire with the round connector located at the top  
of the valve and behind the gas inlet elbow). Then disconnect  
the thermostat (red and white wires) and rocker switch (black  
wires) at terminals #1 & 3.  
5. Remove the socket head screw attaching the cassette/body  
block plate and block plate located in the bottom right end  
of the firebox.  
6. Remove the socket head screw fastening the pilot end of the  
cassette to the burner holder.  
7. Remove the three socket head screws holding the cassette  
(valve/pilot assembly) to the body of the insert.  
fuel Conversion & Cassette installation  
Converting your FireStar™ gas insert between natural gas and  
LP can be accomplished by either changing the Quick Change  
Cassette (valve and pilot assembly) or installing a conversion kit  
(regulator, burner orifice and pilot orifice). Only a qualified service  
technician should perform the conversion, as it requires discon-  
necting the gas supply line and other procedures that should only  
be performed by a qualified technician.  
Cassette Removal  
1. Be sure the gas supply is off and fan power cord is discon-  
nected before beginning the conversion. Disconnect the gas  
supply from the insert being careful not to apply pressure to  
the valve in the process.  
2. Remove the log set and brick panels, (see “Brick Panel & Log  
Installation)  
8. The cassette can now be removed by rotating the valve for-  
ward and out to the right.  
9. Install new, converted or serviced cassette in the reverse order  
of removal. All parts and wires must be correctly reinstalled  
3. Remove the burner by lifting the left end and pulling the burner  
gently through the block plate and past the pilot assembly.  
to ensure safe and proper operation of the unit.  
Conversion kit  
Please see instructions provided with conversion kit.  
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.  
19  
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Troubleshooting  
NOTE: When troubleshooting the gas control system, be sure the external gas shut off valve, located at the gas sup-  
ply inlet is in the “ON” position.  
IMPORTANT: Call your gas supplier or plumber for additional help with any gas control problem. Valve system  
troubleshooting should only be accomplished by a qualified service technician.  
SYMPTOM  
PROBABLE CAUSE  
CORRECTIVE ACTION  
Thin black coating (soot)  
forms on the viewing  
glass, logs, or firebox  
1) Improper log or  
ember placement  
ꢀ) Improper air shutter  
setting  
1) See Log Set Installation on Pages 9 & 10. If there is soot in one specific location, the  
rockwool below this location needs to be adjusted. This can be done by pulling embers  
forward slightly. If the flames have soot tails, the shutter will need to be opened.  
ꢀ) If sooting continues open air shutter (see Air Shutter Adjustment on Page 12)  
ꢁ) Not enough combus- ꢁ) Check for debris obstructing air flow in valve compartment under insert or in front of  
tion air  
4) Incorrect gas pres-  
sure  
lower venting.  
4) Have gas supplier check for correct gas pressure (7" W.C. natural gas: 11" W.C. pro-  
pane gas)  
Humming or whistling  
coming from insert.  
1) Normal operating  
noise  
ꢀ) Obstructed orifice  
opening  
1) See Quiet Operation on Page 15. The noise may be reduced by slightly turning down  
the flame. Turning the flame down will reduce the heat output of the insert.  
ꢀ) If noise is excessive or is “whistling” have your gas supplier check the regulator and  
orifices and replace if necessary.  
ꢁ) Defective regulator  
ꢁ) If noise is excessive or is “whistling” have your gas supplier check the regulator and  
orifices and replace if necessary.  
A change in flame appear- 1) A change in gas  
ance or burner operation. pressure  
ꢀ) Improper ember  
1) Have your gas supplier check for correct gas pressure (7" W.C. / po. C.E. [1.74 kPa]  
natural gas; 11" W.C. / po. C.E. [2.74 kPa] LP gas). NOTE: NEVER BLOCK OR OBSTRUCT  
AIR INTAKE OR OUTLET VENTS.  
placement  
ꢀ) See Log Set Installation Instructions.  
Spark igniter will not light 1) No gas supplied to  
1) Check gas supply. To purge, hold in gas cock on valve for 1-2 minutes and try again.  
ꢀ) Check for spark at electrode and pilot, if no spark and electrode wire is properly con-  
nected, replace igniter and igniter wire.  
ꢁ) Using a match, light pilot. If pilot lights, turn off pilot and trigger the igniter again.  
If pilot lights, an intermittent gas/air supply may be the problem, if longer purge will  
pilot after repeated tries.  
unit or air in line  
ꢀ) Defective igniter (no  
spark at electrode)  
ꢁ) Defective or mis-  
aligned electrode at pilot not light - check gap between electrode and pilot - should be 1/8 inch (3 mm) to have a  
(spark at electrode)  
strong spark. If OK, replace pilot.  
Pilot will not stay lit after  
carefully following lighting Switch shut down.  
1) Vent Safety Snap  
1) Snap switch activated, have venting system inspected for blockage, down draft or  
bad snap switch.  
instructions.  
ꢀ) Improper Flame  
impingement  
ꢁ) Low gas inlet pres-  
sure  
ꢀ) Check pilot flame adjustment (see "Maintenance" section).  
ꢁ) Check inlet pressure and adjust pilot if necessary.  
4) Be sure wire connections from thermopile are tight at gas valve terminals and at vent  
safety snap switch.  
4) Defective thermopile 5a) Either rocker switch or thermostat wires may be grounded. Remove wires from valve  
5) Bad connection  
6)Defective automatic  
valve operator  
terminals. If pilot stays lit, trace switch wiring for a ground. May be grounded to insert or  
gas supply.  
5b) Check open circuit millivolt output of thermopile. Reading should be greater than  
325mV. Also check thermopile wire for kinks that can cause loss of mV. Replace faulty  
thermopile if wire is okay and reading is less than 325mV.  
6)Turn valve knob to “ON” and thermostat (if installed) to 90º. Millivolt meter should read  
greater than 100 mV. If reading is OK and burner does not turn on, replace gas valve  
(qualified service technician only).  
Pilot burning, but no  
flame on main burner with ꢀ) Rocker switch,  
valve knob “ON”, rocker  
switch and thermostat  
“ON”.  
1) Pilot has gone out  
1) See Lighting Instructions.  
ꢀ) Disconnect rocker switch and thermostat wires at terminals 1 and 3 on valve. Jumper  
across from 1 to 3 with pilot lit. If burner comes on either rocker switch, thermostat, or  
wiring is not functioning. If not, jumper wires across switch wires at gas valve. If burner  
comes on, wires are faulty or connections are bad.  
thermostat, or wires  
defective  
ꢁ) Thermopile may not  
be generating sufficient ꢁ) Check thermopile with millivolt meter (see Maintenance and Servicing), recheck  
millivolts  
4) Plugged burner  
orifice.  
symptom #2.  
4) Check burner for stoppage and remove.  
ꢀ0  
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REPLACEMENT PARTS LIST  
PART # DESCRIPTION  
H5952 #33 NG Main Burner Orifice  
H5953 #35 NG High Elevation Main Burner Orifice  
H5951 #50 LP High Elevation Main Burner Orifice  
H5843 2” Bottom Trim Piece  
H5950 #49 LP Main Burner Orifice  
H5860 4 Piece Log Set  
H5844 Air Control Burner Pan  
H5842 Baffle Plate  
H5519 Baffle Plate Holder Brackets  
75145 Black Door w/Glass  
H5874 Blower Power Cord  
H5877 Blower Speed Control  
H5996 Blower Speed Control And Housing (Includes 2 Rivets)  
H5997 Blower w/Mounting Bracket  
H5866 Brick Panel Set  
H5934 Burner Tube  
H5740 Cassette Assembly NG (For LP Installations, Also Order LP Conversion Kit)  
H5863 Volcanic Stone  
H5985 Decorative Gold Bar On Lower Stove Body  
H5986 Decorative Nickel Bar On Lower Stove Body  
H5905 Door Rope (Per Foot) Order 8 Ft. for each door  
75146 Gold Door w/Glass  
H5875 Heat Sensed Blower Snap Switch  
H3106 Left-hand Side Door (Mounting Brackets & Blower Speed Control Installed)  
H5881 LP Pilot Assembly (Includes Thermopile, Electrode And Wire)  
H5930 LP Pilot Orifice  
H5940 LP Regulator  
H5744 Main Burner On/Off Rocker Switch  
H5995 Main Burner On/Off Switch Wires  
H5981 Main Door Decorative Gold Bars Each (2 Per Stove)  
H5982 Main Door Decorative Nickel Bars Each (2 Per Stove)  
H6000 Middle Bay Glass W/glass Tape Installed  
H5880 NG Pilot Assembly (Includes Thermopile, Electrode And Wire)  
H5949 NG Pilot Orifice  
H5939 NG Regulator  
75147 Nickel Door W/glass  
H5745 Piezo Igniter  
H5999 Rheostat Wire  
H5954 Robertshaw Main Gas Control Valve LP  
H5937 Robertshaw Main Gas Control Valve NG  
H5864 Rock Wool (embers)  
H3107 Side Bay Glass W/glass Tape Installed Each (2 Per Stove)  
H5998 Snap Switch Wire  
H5882 Thermopile  
75254 Top Trivet  
H5993 Vent Safety Snap Switch W/bracket  
H5994 Vent Safety Snap Switch Wires  
ꢀ1  
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Safety / Listing Label  
ꢀꢀ  
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Lighting Label  
ꢀꢁ  
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Normally, all parts should be ordered through your Lennox Hearth  
Products distributor or dealer. Parts will be shipped at prevailing prices  
at time of order.  
WARRANTY  
Your gas appliance is covered by a limited warranty (provided with appli-  
ance). Please read the warranty to be familiar with its coverage.  
When ordering repair parts, always give the following information:  
Retain this manual. File it with your other documents for future refer-  
ence.  
1. The model number of the appliance.  
ꢀ. The serial number of the appliance.  
ꢁ. The part number.  
4. The description of the part.  
5. The quantity required.  
PRODUCT REFERENCE INFORMATION  
We recommend that you record the following important information  
about your fireplace. Please contact your Lennox Hearth Products dealer  
for any questions or concerns. For the number of your nearest Lennox  
Hearth Products dealer, please call 1-800-9-Lennox.  
6. The installation date of the appliance.  
If you encounter any problems or have any questions concerning the  
installation or application of this system, please contact your dealer.  
REPLACEMENT PARTS  
LENNOX HEARTH PRODUCTS  
1110 West Taft Avenue  
Orange, CA 9ꢀ865  
See Page 21 for a complete replacement parts list. Use only parts sup-  
plied from the manufacturer.  
Your Fireplace Insert's Model Number___________________________________  
Your Fireplace Insert’s Serial Number ___________________________________  
The Date On Which Your Fireplace Insert Was Installed______________________  
The Type of Gas Your Fireplace Insert Uses_______________________________  
Your Dealer's Name _________________________________________________  
Fuel Type (Check one) c Natural Gas c Propane Gas (LP)  
Lennox™ reserves the right to make changes at any time, without notice, in design,  
materials, specifications, prices and also to discontinue colors, styles and products.  
Consult your local distributor for fireplace code information.  
Printed in U.S.A. © Lennox Hearth Products ꢀ007  
1110 West Taft Avenue • Orange, CA 9ꢀ865  
P/N 775,ꢀꢀ5M REV. A 06/ꢀ007  
ꢀ4  
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