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
timeorfingerprintswillremainpermanently.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
aroundthefireplaceshallnotbealteredbytheinstallation
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-engineeredfireplace
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
visibleuponremovalofthefireplaceinsert. 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”
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
trimpiecesandfastenwithflatscrewdriver. 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.
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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
(usinga5/32”hexwrench)throughtheinsertbottomintothefiller
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. See“FlameColorandBehavior”
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.
1ꢁ
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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
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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.
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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
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
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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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