INSTALLATION AND OPERATION MANUAL
Pellet-Fired
Fireplace Insert
Save These Instructions
For Future Reference
P/N 775,229M, Rev. B, 08/2008
Pellet Insert
Model Winslow™ (PI40)
A French manual is available upon request. Order P/N 775,229CF.
Ce manuel d’installation est disponible en francais, simplement en faire la demande. Numéro de la pièce
775,229CF.
Portland
US
These appliances must be properly installed and operated in order to prevent the possibility
of a house fire. Please read this entire manual before installation and use of this pellet
fuel-burning room heater. Failure to follow these instructions could result in property
damage, bodily injury or even death. Contact your local building or fire officials
to obtain a permit and information on any installation requirements and
inspection requirements in your area.
Report No. 050-S-14b-2
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.
• Lennox™ pellet-burning appliances are designed for use as a supple-
mental heater. They are not intended for continuous use as a primary
heat source.
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Pellet Fuel................................................................ Page.19
Corn Fuel................................................................. Page.19
Cautions.................................................................. Page.19
Cleaning and Maintenance ............................................. Page.20-23
Burn Pot Cleaning ................................................... Page.20
Cleaning Glass......................................................... Page.20
Cleaning Heat Exchanger......................................... Page.20
Cleaning Flue Gas Passageways.............................. Page.20
Cleaning Combustion Blower .................................. Page.21
Cleaning Vent Pipe .................................................. Page.21
Removing Ash from the Firebox.............................. Page.21
Cleaning Convection Blower.................................... Page.22
Adjustable Hopper................................................... Page.22
Cleaning “Proof of Fire” Switch............................... Page 22
Front Door Opening and Removal........................... Page.23
Side Door Removal ................................................. Page.23
Component Location and Functions............................... Page.24-25
Igniter...................................................................... Page.24
Vacuum Switch ....................................................... Page.24
Auger and Auger Motor .......................................... Page.24
Over Temperature Snap Switch............................... Page.24
Proof of Fire Snap Switch........................................ Page.24
Convection Blower Snap Switch.............................. Page.24
Draft Adjuster.......................................................... Page.25
Wiring Diagram....................................................... Page.25
Diagnostic Codes................................................................ Page.26
Troubleshooting.................................................................. Page.26
Replacement Parts.............................................................. Page.27
Accessories......................................................................... Page.28
Heat Kit Instructions .......................................................... Page.29
Pellet Insert ZC Kit Assembly Instructions.......................... Page 30
ZC Framing Dimensions for
CONGRATULATIONS!
When you purchased your new pellet stove, you joined the ranks of
thousands of individuals whose answer to their home heating needs,
aesthetics, efficiency and our environment. We extend our continued
support to help you achieve the maximum benefit and enjoyment avail-
able from your new pellet stove.
It is our goal at Lennox Hearth Products to provide you, our valued
customer, with an appliance that will ensure you years of trouble free
warmth and pleasure.
Thank you for selecting a Lennox Hearth Products stove as the answer
to your home supplemental heating needs.
TABLE OF CONTENTS
Important Safety Warnings ................................................... Page.2
Using this Manual................................................................. Page 3
Planning Your Installation..................................................... Page 4
Selecting a Location.............................................................. Page 4
Features and Specifications .................................................. Page.5
Insert Dimensions................................................................. Page.6
Minimum Fireplace Size........................................................ Page.6
Clearances to Combustibles.................................................. Page.7
Hearth Protection.................................................................. Page.7
Installation ....................................................................... Page.8-17
Control Board Installation.......................................... Page.8
Venting...................................................................... Page.8
Vent Termination Requirements................................ Page.8
Vent Termination Locations....................................... Page 9
Insert Leveling......................................................... Page.10
Surround Installation............................................... Page.10
Mobile Home Installations....................................... Page.11
Outside Air Installations .......................................... Page.12
Thermostat installation............................................ Page.12
Door Trim Installation Instructions ......................... Page.12
Door Grill Installation Instructions ......................... Page.14
Brick Panel Installation Instructions........................ Page.15
Log Set Installation Instructions ............................ Page.17
Operation ....................................................................... Page.14-19
Control Board.......................................................... Page.18
Filling the Hopper.................................................... Page.18
Lighting................................................................... Page.18
Manual Operation.................................................... Page.18
Thermostat Operation ............................................. Page.18
Shut Down .............................................................. Page.19
Paint Curing ............................................................ Page.19
Convection Blower Operation.................................. Page.19
Operating Sounds ................................................... Page.19
Combustible Hearth /Floor ........................................... Page.33
ZC Framing Dimensions for Non-
Combustible Hearth /Floor ........................................... Page.34
Product Reference Information........................................... Page.36
USING THIS MANUAL
Please read and carefully follow all of the instructions found in this
manual. Please pay special attention to the safety instructions provided
in this manual.
PRODUCT IS SUBJECT TO CHANGE WITHOUT NOTICE
3
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Surge Protectors - A surge protector is recommended to ensure the
stove’s electrical components are not damaged due to a surge in the
electrical supply. Only high quality protectors should be used - cheap
ones do not provide the protection needed.
PLANNING YOUR INSTALLATION
Questions To Ask Local Building Official
Acorrectinstallationiscriticalandimperativeforreducingfirehazardsand
perilous conditions that can arise when wood pellet burning appliances
are improperly installed. The installer must follow all of the manufactur-
ers’ instructions.
Smoke Detectors - Since there are always several potential sources of
fire in any home, we recommend installing smoke detectors. If possible,
install the smoke detector in a hallway adjacent to the room (to reduce
the possibility of occasional false activation from the heat produced
by these appliances). If your local code requires a smoke detector be
installed within the same room, you must follow the requirements of
your local code. Check with your local building department for require-
ments in your area.
WARNING
Check all local building and safety codes before
installation.Theinstallationinstructionsandappro-
priate code requirements must be followed exactly
andwithoutcompromise.Alterationstothestoveare
not allowed. Do not connect the stove to a chimney
system serving another stove, appliance, or any air
distributionduct.Failuretofollowtheseinstructions
will void the manufacturers warranty.
Installation/MaintenanceStandards-NationalFireProtectionAssocia-
tion – The primary NFPA standard that refers to installation and main-
tenance of pellet appliances and venting is NFPA 211 – Latest Edition:
Chimneys, Fireplaces, Vents, and Solid Fuel appliances.
SELECTING A LOCATION
The design of your home and where you place your stove will determine
its value as a source of heat. This type of appliance depends primarily on
air circulation (convection) to disperse its heat, and therefore, a central
location is often best. There are other practical considerations, which
must be considered before a final selection of locations is made.
• Existing Chimneys
The installation of this appliance must conform to local codes and appli-
cable state and federal requirements. Familiarity with these requirements
before installation is essential. Important considerations to discuss with
local building officials include:
1. Applicable codes (i.e. Uniform Mechanical Code, State or Regional
Codes).
• Pellet Fuel Storage
Electrical codes:
In USA, NEC, ANSI/NFPA 70 – Latest Edition
In Canada, CSA C22.1 – Latest Edition
• Aesthetic Considerations
• Roof Design (rafter locations & roof pitch)
• Room Traffic
Power Supply Requirements
• Proximity to Combustibles
• Electrical Wiring
Thepowercordmustbepluggedintoastandard,120volt,60Hzgrounded
electrical outlet. The power supply cord must be routed to avoid contact
with any of the hot or sharp exterior surface areas of the stove. When
installed in a manufactured home, the appliance must be electrically
grounded to the steel chassis (see Mobile Home Installations on Page
11, for additional requirements). These requirements must be met unless
otherwise specified by state or local authorities.
CAUTION
The body of these appliances are very heavy. The
use of a heavy duty escalara (stair step hand truck)
is recommended for lifting the appliance body.
Electrical
• The fireplace insert requires 120 volts AC for operation.
• Maximum wattage is 700.
NEGATIVE PRESSURE WARNING
• Igniter wattage is 400.
• Normal operating wattage is 300.
This appliance is not designed to be operated in a negative pressure. Very
airtight homes with large kitchen exhaust fans, or homes with furnace
cold air returns located in close proximity to the stove may create nega-
tive pressure in the same room as the heating appliance. This can create
dangerouscondition, drawingcombustionby-productsintothehome. Be
sure your home has adequate makeup air to eliminate negative pressures
caused by the above-mentioned sources. Outside air connected to the
appliance probably will not resolve such a problem as the stove is not the
source of negative pressure. Lennox Hearth Products accepts no liability
for damages resulting from negative pressures described here.
Electrical Generator Operation
Your Winslow™ PI40 insert can be powered with a gas driven electrical
gererator.However,thegenerator’selectricalregulatormaynotbecompat-
ible with the insert’s electronics. The higher the quality of the gererator,
the greater the chance that it is compatible with the insert.
WARNING
Electrical grounding instructions: 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 ground-
ing prong from this plug. Do not route power cord
under or in front of appliance.
Ventilation Requirements - Provide adequate air for combustion. The
freshairrequirementsofthisappliancemustbemetwithinthespacewhere
it will be installed. Ventilation is essential when using a solid-fuel-burning
heater. In well insulated and weather tight homes, it may inhibit the rate
the exhaust flows through the venting system (caused by a shortage of
air in the home). The lack of air is caused by many common household
appliances which exhaust air from the home (such as a furnace, heat
pump, air conditioner, clothes dryer, exhaust fans, fireplaces, and other
fuel burning appliances). Also, the combustion process of this heater
uses oxygen from inside the dwelling. If the available fresh air delivery
in the dwelling is insufficient to support the demands of these appli-
ances, problems can result (i.e. excessive negative pressure will result
in performance problems. To correct this problem it may help to open
a window (preferably on the windward side of the house) or install an
outside combustion air duct to the appliance.
2. Local amendments
3. Is a permit required - cost. You may wish to contact your insurance
company to ask if they require this.
4. If outside combustion air is required
5. Rooms where the installation is not allowed
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• BTU CONTENT: There are a number of variations in pellet fuels that are
not included in PFI standards. For example, BTU (heat value) content
may range from just under 8,000 to almost 9,000 Btu, depending
upon species and region of the country and other variables.
FEATURES AND SPECIFICATIONS
Installation Options
• Residential
• Vented vertical and horizontal (see venting instructions)
• Manufactured home and mobile home
• Thermostat or manual operation
• Bedrooms
Corn Specifications: Use only clean-shelled corn with a moisture content
less than 15% and approximate fuel value of 7000 BTU/lb (16,200 kJ/kg).
Do not attempt to burn corn with higher moisture content or burn lesser
grade fuels. Do not burn other types of agricultural pellets or by-products
(alfalfa, cherry pits, olive pits, nut shells, etc.) as they are not permitted
to be burned in these appliances.
Heating
• Max. feed rate is 4.5 pounds/hour or 37,500 BTU/hour
• Min. feed rate is 1.8 pounds/hour or 15,120 BTU/hour
Weight - 270 pounds
Venting
Hopper Capacity
This appliance is approved for venting with Type L and Type PL pellet vent
pipe. The flue collar on the fireplace insert accepts 3” diameter pipe. The
vent pipe can be installed vertically or horizontally (see Venting section
for recommended installations).
55 pounds (adjustable down to 40 pounds to fit into small fireplaces)
Listing Information
The Winslow™ PI40 insert is safety listed with the following agencies:
• OMNI-Test Laboratories, Inc., Portland Oregon to ASTM E 1509
• US EPA List of Exempt Wood Heating Appliances
• Colorado Approved Pellet Stoves
The combustion air for this fireplace insert is drawn through a pipe at
the lower rear of the fireplace insert. For mobile home installations a 2”
ID flex line or pipe can be attached to the fireplace insert’s air intake to
draw air from outside the house.
Appearance Options
TheWinslowPI40insertcanbeorderedwiththefollowingdoortrims,grills,
surround (flange) assemblies, log set and brick panel options :
Thermostat
This fireplace insert can be operated manually or with a thermostat.
Door Trim Kits
Black
Grill Kits
Black
Lighting
79038
79034
79037
79035
79036
79000
79001
79002
79022
79039
This fireplace insert is equipped with an electric self ignitor for ease of
ignition.
Gold
Gold
Nickel
Brush Nickel
Black Nickel
Nickel
Brush Nickel
Black Nickel
Fuel Specifications
This insert is designed to burn wood pellet fuel. In addition, a corn/wood
pelletmixture,withamaximumof50percentcorncanbeburned.Burning
any other fuel that is not approved for use with this appliance will void the
appliance warranty. IMPORTANT: The corn/wood mix needs to be mixed
evenly before being put in the Winslow™ pellet insert hopper.
Surround Kits
29” Ht. x 41” Wd. Black Trim
29” Ht. x 48” Wd. Black Trim
33” Ht. x 41” Wd. Black Trim
33” Ht. x 48” Wd. Black Trim
79004
79005
79006
79007
Wood Pellet Specifications: This appliance has been designed to burn
wood residue pellets with up to 3% ash content. Dirty fuel will adversely
affect the performance of the insert. Any questions regarding pellet fuel
3ꢀ” ZC Surround Kit *
29” Ht. x 41” Wd. x 3” Deep
79032
* This black surround kit positions the insert 3” forward so that it will
allow the insert to fit into a fireplace with a narrower width in the front
(32” min.). Note: No trim kits are available for this kit at this time.
CAUTION
Surround Trim Kits
THE USE OF UNAPPROVED, DIRTY, WET AND/OR
HIGH SALT CONTENT FUEL WILL VOID THE WAR-
RANTY!
Trim/Black 29” Ht. x 41” Wd.
Trim/Black 29” Ht. x 48” Wd.
Trim/Black 33” Ht. x 41” Wd.
Trim/Black 33” Ht. x 48” Wd.
Trim/Gold 29” Ht. x 41” Wd.
Trim/Gold 29” Ht. x 48” Wd.
Trim/Gold 33” Ht. x 41” Wd.
Trim/Gold 33” Ht. x 48” Wd.
Trim/Nickel 29” Ht. x 41” Wd.
Trim/Nickel 29” Ht. x 48” Wd.
Trim/Nickel 33” Ht. x 41” Wd.
Trim/Nickel 33” Ht. x 48” Wd.
H5143
H5145
H5144
H5146
75036
75038
75040
75042
75037
75039
75041
75043
Woodpelletsmanufacturedtothepelletfuelsinstitute(P.F.I.)certification
standardareavailableintwogrades,StandardandPremium.Theprimary
difference between the two is the ash content of the pellets.
The P.F.I. specification for standard grade and premium grade residential
pellet fuel is as follows:
• CHLORIDES (Salt): Less than 300 p.p.m. to avoid insert and vent
rusting.
Log Set
H5142
79030
• BULK DENSITY: 40 lb. / Cu. Ft. minimum
• MOISTURE CONTENT: 8% maximum
• ASH CONTENT: < 3% maximum (standard grade) < 1% maximum
(premium grade)
Brick Panel Kit - Required
• FINES: 0.5% maximum through a 1/8” screen
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ꢀ-1/ꢀ” Minimum Screen Pocket is Needed for the Control
Board (not applicable if P/N 7903ꢀ ZC Surround Kit is used*)
INSERT DIMENSIONS
Front View
ꢀ3” (584mm)
Minimum
15-1/ꢀ”
(394mm)
15”
(381mm)
ꢀ6-1/4”
(667mm)
36” (914mm)
Minimum*
Control
Board
Side
Surround
Panel
ꢀ3-3/8”
(594mm)
*
This fireplace insert can fit into a fireplace with a narrower width in the front
(32” min. instead of 36” min.) when the 3” Deep ZC Surround Kit is used (P/N
79032). See Figure 11C on Page 11 for more information. Please take note
that because the appliance will be positioned in a more forward position on
the existing hearth, additional floor protection may need to be added to the
front of the appliance (see Figure 7).
ꢀ6”
(660mm)
Figure 1
Figure 3
Side View
Flex Pipe
Existing 8” Flue
Exhaust Collar
14-3/8”
(365mm)
15-1/4”
(387mm)
8-3/4”
(ꢀꢀꢀmm)
Min.
19”
(483mm)
Figure 4
15”
(381mm)
ꢀ9-3/4”
(756mm)
Figure 2
MINIMUM FIREPLACE SIZE
Figures 3 and 5 shows the minimum sized fireplace required for the
Winslow™ PI40 insert when any of the four non-extended surround
sizes are used.
With the hopper at its largest size (as shipped from the factory), the
fireplace needs to be a minimum of 22-1/2” (572 mm) high. When the
hopper is adjusted to its smallest size (see “Adjustable Hopper”), the
fireplace needs to be a minimum of 19” (483 mm) high.
W/Hopper Extension ꢀ1-13/16” (554mm)
W/O Hopper Extension 18-5/16” (465mm)
Figure 5
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
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HEARTH PROTECTION
CLEARANCES TO COMBUSTIBLES
The floor protector must be a non-combustible material extending
beneath the insert from the surround panels forward and to the front
and sides as shown in Figure 7. Important, if anything other than a
masonry hearth is used in the installation you must use the Heat Kit
(Cat. No. 790ꢀ4).
IMPORTANT
• Minimum clearances specified may not allow
for ease of operation and maintenance (please
take this in to account when planning the instal-
lation).
• Recommended clearance zone from the front
of the appliance to combustibles is 4 feet mini-
mum.
• Clearances to combustibles for the appliance
can only be reduced by means approved by the
regulatory authority.
Hearth Protection
(shaded gray)
Insert Base
INSTALL VENT AT CLEARANCES SPECIFIED BY THE VENT
MANUFACTURER.
Firebox Front Edge
Important: The control board attaches to the back of the right
side surround panel. Therefore, the width of the fireplace firebox
needstobe36”(914mm)wideatthefrontiftheinsertwithcontrol
board is to slide into the firebox. Extended surround panels are
available to accommodate narrower fireboxes.
6”
(15ꢀmm)
6”
(15ꢀmm)
3”
(76mm)
3”
6”
(15ꢀmm)
Floor Protection
(76mm)
Figure 7
Minimum Size Floor Protection
10”
(ꢀ54mm)
Max.
9-1/ꢀ”
(ꢀ41mm)
31-3/4”
(807mm)
7-1/ꢀ”
(191mm)
1-1/ꢀ”
(38mm)
19-1/4”
(489mm)
6”
Outline of Insert Base
(15ꢀmm)
7-7/16”
(189mm)
6”
(15ꢀmm)
ꢀ3-3/8”
(594mm)
6-11/16”
(170mm)
6-11/16”
(170mm)
18-3/8”
(467mm)
Figure 8
3”
(76mm)
Floor Protection
Zero Clearance Kit and Heat Kit Installation
Figure 6
The Winslow™ PI40 insert has a Zero Clearance Kit (Cat. No. 79025) and
a Heat Kit (Cat. No. 79024) approved for new construction or remodel
installations. See Zero Clearance and Heat kit installation instructions at
the back of this manual for requirements. Both kits have been tested and
approved through OMNI Testing Laboratories Inc.
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
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Vent Termination Requirements:
INSTALLATION
If the insert is not vented vertically, the following apply:
Control Board Installation
1. Do not terminate the vent in any enclosed or semi-enclosed areas
such as a carport, garage, attic, crawlspace, narrow walkway, closely
fenced area, under a sundeck or porch, or any location that can build
up a concentration of fumes such as stairwells, covered breezeway,
etc.
The Winslow PI40 insert is shipped with the control board wrapped and
placed behind the firebox. To install the control board, unwrap it and
the right side surround panel found in the surround kit. There are four
prongs protruding from the surround. Place the two slots in the bottom
and the two holes in the top of the control board over the four prongs
on the surround panel. Install the surround panels following the instruc-
tions on Page 10.
2. Vent surfaces can become hot enough to cause burns if touched.
Non-combustible shielding or guards may be required.
3. Terminationmustexhaustabovetheinletelevation.Itisrecommended
that at least five feet of vertical pipe be installed outside when the
insert is vented directly through a wall. This will create a natural draft
to prevent the possibility of smoke or odor during appliance shut
down or power failure and avoid exposing people or shrubs to high
temperatures.
Venting
Pellet pipe type PL, L, or listed pellet flex liner must be used to vent the
Winslow™PI40insert.Theinsert’sfluecollaris3”indiameter.Theinsert’s
combustion blower pressurizes and pushes flue gases out the pellet pipe.
All pipe joints should be locked together or screwed with three screws if
the pipe does not have a locking system. The pipe joints can be sealed
with high temperature silicone if there is a possibility of flue gases leaking
into the living area. The pipe should be fastened with three screws to the
insert’s flue collar. The longer the run of pipe and the more elbows used,
the greater the resistance to the flow of flue gases. Four inch diameter
pellet pipe is recommended for pipe runs greater than 15 feet or when a
number of elbows are used. A 3-4” increaser can be used to connect the
4” pipe to the 3” flue collar. The outside air pipe may run up the chimney,
horizontally, or down provided the structural integrity of the fireplace and
chimney system are maintained. DO NOT INSTALL A FLUE DAMPER IN
THEEXHAUSTVENTINGSYSTEMOFTHISUNIT.DONOTCONNECTTHIS
UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
4. The vent should terminate no less than four feet below, no less than
four feet horizontally from, and no less than one foot above doors
and windows, or gravity/ventilation air inlets into the building.
5. The distance between the bottom of termination and grade should be
12” minimum. The distance between the bottom of the termination
and a public walkway should be a minimum of seven feet.
6. Locate the vent termination at least two feet away from combustible
materials such as shrubs, plants, grass, fences, roof overhangs, and
adjacent buildings.
8
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Vent Termination Locations
Air Supply Inlet
Vent Terminal
Vertical Terminal
Area Where Terminal Is Not Permitted
24”
(610mm)
Vertical Terminal
G
(From Eave)
24”
(610mm)
A
D
E
Fixed Closed
B
B
N
C
H
L
M
B
B
K
F
J
A
B
Able To Open
A = Clearance above grade, veranda, porch, deck, or balcony (min.
12”/30cm)
L = Clearance to a mechanical air supply inlet *(min. 120”/3.1m)
M = **Clearance above paved sidewalk or a paved driveway located on
public property *(min. 84”/2.1m)
B = Clearance to window or door that may be opened (min. 12”/30cm
above - 48”/1.2m below and to the side)
N = ***Clearance under veranda, porch, deck, or balcony (min.
12”/30cm)
C = Clearance to permanently closed window *(min. 12”/30cm)
D = Vertical clearance to ventilated soffit located above the terminal
within a horizontal distance of *(min. 24”/60cm) from the center-
line of the terminal (min. 22”/55cm) check with local code.
E = Clearance to unventilated soffit *(min. 12”/30cm)
F = Clearance to outside corner *(min. 12”/30cm)
Note:
*
Local codes or regulations may require different clearances.
**
A vent shall not terminate directly above a sidewalk or paved
driveway which is located between two single family dwellings
and serves both dwellings.
G = Clearance to inside corner *(min. 12”/30cm)
H = Not to be installed above a meter/regulator assembly within *(min.
36”/90cm) horizontally from the centerline of the regulator.
J = Clearance to service regulator vent outlet *(min. 72”/1.8m)
K = Clearance to non-mechanical air supply inlet to building or the
combustion air inlet to any other appliance *(min. 48”/1.2m)
*** Only permitted if veranda, porch, deck, or balcony is fully open on
a minimum of two sides beneath the floor.
Figure 9
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
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The recommended pipe installation is running the pellet pipe
from the insert all the way to the top of the chimney. However,
the pipe may terminate inside the chimney above the damper if
the chimney is sealed below the pellet pipe termination with a
block off panel (see Figure 10). The insert can also be vented
horizontally out the back of the fireplace, but a listed pellet pipe
thimble must be used if the pipe goes through a combustible wall
and the structural integrity of the fireplace and chimney system
must be maintained.
*The block off panel should be
air tight to ensure smoke does
not enter the house and to help
establish chimney draft when the
pipe does not terminate at the top
of the chimney.
Insert Leveling
Inside the firebox is a bag of hardware with four 4”x 3/8” carriage
bolts. If the insert needs to be leveled, install one of these bolts
(from the bottom side) in the nuts at the left and right rear of the
baseoftheinsert.Openthefrontdoorandremovetheboltsscrewed
into the nuts at the left and right front of the firebox floor.
Damper
From the bottom outside of the insert, install the remaining two
carriage bolts in the nuts from which the bolts were just removed.
Azeroclearancefrontsupportisavailabletofillthespacebetween
the insert and hearth.
Block Off Panel*
Surround (Flange) Installation
To install the surround panels:
1. Remove the side doors (see Page 23) to access the surround
mountingbrackets. Removethespeednutsfromthepartsbag
found in the firebox. Install the six speed nuts (with the flat
surface forward) on the six surround mounting bracket holes,
three on each side of the insert. A flat-bladed screwdriver may
help in installing the nuts. See the expanded view in Figure
11A.
Figure 10
2. Screw the six 1/4” truss head screws partially into the speed
nuts (see A in Figure 11A).
3. The side surround panel with the small access door for the
control board goes on the right side of the insert (see Figures
11B and 11C). Slide the slots in the side surround panels and
top surround panels behind the heads of the truss screws.
Tighten all six truss screws after shifting surround panels to
eliminate space between the side and top surround panels.
4. Install two spring clips approximately five inches from each
end of each of the three trim pieces. The spring clips should be
installed in the channel of the trim with the curved portion of
the clip to the front toward the rounded surface of the trim.
5. Placethelongesttrimpiecewiththeroundedsurfaceoutalong
theedgeofthetopsurroundpanelwiththespringclipsslightly
behindthesurroundpanel. Pullthetrimforward, compressing
the spring clips, and slide the trim down onto the surround.
6. Insert the elbowed retainer in the mitred end of the side trim
pieces and fasten with flat screwdriver. Insert the other end
of the retainer in the end of the already installed top surround
trim and slide side trim onto the edge of the side surround
compressing the spring clips in the process. Repeat the same
steps for the other side trim. Fasten the elbowed retainer
securely in the top surround making a nice mitred corner.
Speed Nut
Expanded View
A
A
A
Figure 11A
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Mobile Home Installations
Fireplace Installation Using Standard Surround Kits
(P/N 79004, 79005, 79006 and 79007)
ThefollowingstepsarerequiredforinstallationoftheWinslow™
PI40 insert in mobile homes. See Figure 12.
FIREPLACE OPENING C/L
1. ConnectingtheWinslowPI40inserttooutsidecombustion
airisoptional,exceptinmobilehomeinstallationsandwhen
required by local building codes. The insert’s air intake will
accept 2” ID pipe to accommodate outside air installations.
The air intake on the exterior of the home should always
be located substantially below the flue termination and
terminate with a cover to keep out weather and pests.
2. The insert must be fastened to the hearth/floor using lag
screws. The screws can be inserted through the holes in
the base located behind the side doors. If the hearth is
concrete or masonry, use proper lag bolts and methods
designed for anchoring to masonry or concrete.
18"
13-1/2"
6"
CONTROL BOARD
3. The insert must be grounded with a #8 or larger copper
wire.
11"
41" SURROUND WIDTH
WARNING: DONOTINSTALLTHISINSERTINASLEEP-
ING ROOM IN A MANUFACTURED HOME.
19-1/4"
CAUTION: THE STRUCTURAL INTEGRITY OF THE
MANUFACTURED HOME FLOOR, WALL, AND CEIL-
ING/ROOF MUST BE MAINTAINED.
138°
7-7/16"
HEARTH / FLOOR PROTECTION
31-3/4"
18-3/8"
6-11/16"
Figure 11B
Termination Cap
Cap
Fireplace Installation Using 3 Inch Deep ZC Surround Kit
(P/N 7903ꢀ *)
Storm Collar
Flashing
FIREPLACE OPENING C/L
32" FIREPLACE OPENING
18"
13-1/2"
Outside Air Pipe
3"
Listed Pellet Pipe or
Flex Liner
CONTROL
BOARD
DEEP
SURROUND
11"
41" SURROUND WIDTH
21-1/2"
138°
7-7/16"
HEARTH/FLOOR PROTECTION
31-3/4"
18-3/8"
6-11/16"
*
This black surround kit positions the insert 3” forward so that it will allow the insert to fit
into a fireplace with a narrower width in the front (32” min.). Note: No trim kits are avail-
able for this kit at this time. See instruction sheet P/N 506033-05 for more information.
Figure 12
Figure 11C
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Outside Air Installations
Door Trim Installation Instructions
Parts List (A)
ConnectingtheWinslowPI40inserttooutsidecombustionairisoptional,
except in mobile home installations and when required by local building
codes.Thefireplaceinsert’sairintakewillaccept2”IDpipetoaccommodate
outside air installations. The air intake on the exterior of the home should
always be located substantially below the flue termination and terminate
with a cover to keep out weather and pests. The outside air pipe may run
up the chimney, horizontally, or down provided the structural integrity of
the fireplace and chimney system are maintained.
Qty
(2)
Trim Pieces (Gold, Nickel, Brushed Nickel or Black Nickel)
(6) #10 nuts
(6) #10 washers
Tools Needed
Qty
(1) 3/8” nut driver or socket wrench
Thermostat installation
CAUTION: Always ensure that plated surfaces are clean and
free of fingerprints before lighting the insert. Fingerprints
will leave permanent blemishes if left on plated surface when
lit. When installation is complete, the trim should be gently
cleaned with soft cloth and either alcohol or glass cleaner. Do
not overtighten nuts, overtightening can create visible dimples
on the plated surface.
The Winslow PI40 insert can be operated manually or by thermostat.
The insert comes from the factory wired to operate manually, see control
board operation on Page 18. A low voltage thermostat can be installed
on the insert. To install the thermostat:
1. Unplug the insert from the electrical outlet. Open the right side door
and lift out the control board from its retaining brackets. Locate the
light green wiring block at the bottom back of the board (see Figure
13), loosen the two screws B at the back of the block, and remove
the U shaped jumper wire A protruding from the block.
To Install Door Trim:
1. Remove the trim pieces and hardware from its packaging and ensure
that all pieces are present before beginning installation. Take care not to
scratch finished surfaces.
2. Open right and left side door. The side doors swivel open towards the
back of the insert. See Figure 16.
2. Insert a wire from the thermostat into one of the slots from which the
jumperwirewasremoved.Repeatthisprocessfortheotherthermostat
wire.
3. Open front door. Put trim in place by inserting trim studs into the cor-
responding holes in the door (Figures 14 and 15). The top piece of
trim will only fit in one direction, but the bottom piece can be installed
incorrectly. When placing the bottom piece of trim, make sure there
is a 9/16” gap between the top of the trim piece and the glass in the
door. See Figure 18.
Retain the jumper wire for future reinstallation. See Page 18 for ther-
mostat operation instructions.
IMPORTANTNOTE: Installthethermostatperthemanufacturers
instructions, provided with the thermostat. Failure to follow
manufacturers instructions could result in a malfunction. Pay
special attention to the thermostat location requirements. If the
location requirements are not adhered to the appliance, erratic
operation or failure may occur.
Pellet Insert Door
Do not mount the thermostat where it may be affected by:
• Radiant heat from the insert, fireplaces, sun or other heat
sources.
• Drafts or dead spots behind doors or in corners.
• Hot or cold air from ducts.
Trim Pieces
T
Rear View of Control Board
Figure 14
A = Jumper Wire
B = Screws
Wiring Block
A
B
Figure 13
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4. Place one washer on each stud. Using a 3/8” nut driver, snug up the
nuts on each piece of trim. Do not finish tightening the nuts yet. See
Figure 19.
A
Trim Pieces
5. There should be approximately a 7/8” (22 mm) gap between the top
edge of the upper trim and the top edge of the door and a 1-1/2” (38
mm) gap between the bottom trim to the bottom of the door. Visually
inspect the alignment of the trim and adjust if necessary. See Figure
20.
Trim Nuts
#10 washers
6. Finish tightening nuts. CAUTION - DO NOT OVER-TIGHTEN NUTS,
Figure 15
DIMPLING OF THE TRIM WILL OCCUR!!!
Holes for trim studs
Door Handle
Figure 16
Figure 19
Trim stud
Figure 17
Top of Trim
Figure 20
Figure 18
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3. Rotate the grill back to the horizontal position and re-install the four
button head screws through the two holes at each end of the grill and
into the insert body. See Figures 23 and 24.
Door Grill Installation Instructions
Parts Needed
Qty
(4) Button Head Screws (already in place in insert)
Tools Required:
Rotate Grill Back To Horizontal Position
1/8” allen wrench
To install the Grill:
1. Remove the four button head screws from body of the insert with a
1/8” allen wrench. See Figure 21.
Button Head Screw
Figure 23
Re-install Button Head Screws
Figure 21
2. Pull the scraper rod out, rotate the grill vertically, (with the notch to
the left) and slide the grill over the scraper rod (slide the rod between
the third and fourth bar). See Figure 22.
Notch
Slider Rod
Figure 24
Between 3rd & 4th Bar
Figure 22
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2. Remove all pellets and ash from the firebox to ensure a proper fit for
the brick panel.
Brick Panel Installation
Option: Part #79030
3. Insert the brick panel, top first, as shown in Figure 27. The two cut
out corners should be at the bottom.
Kit Contents
Brick Panel (A)
4 Tap Tights (B)
Tools Required
Drill (90° drill recommended)
#18 drill bit
5/32 allen wrench
A
Figure 27
B
Figure 25
4. Make sure that the brick panel is centered, with equal space on either
side of the auger tube. While holding the panel in place, use the drill
with a #18 drill bit to drill out the four holes in the back of the firebox,
as shown in Figure 28.
Note:Thebrickpanelcomespre-paintedwithMetallicBlackpaint. The
brick panel may be painted with any color of high-temp paint (paint
may discolor with use).
1. Remove the front door of the pellet insert. To remove the front door,
open the two side panels, swing open the front door, and lift it up and
off of its hinges. Remove the optional log set, if present, and the burn
pot.
Figure 28
Figure 26
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5. Screw in the four tap tights, included with this kit, using a 5/32 allen
wrench.
6. Replace the burn pot and check that it is firmly in place (if you can
rotate the burn pot it is not installed correctly). If present, install
the optional log set according to the log set installation instructions
(included with your log set).
7. Re-hang the door by reversing the instructions in step 1.
Figure 29
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Log Set Installation Instructions
Kit Contents
(refer to Figure 30)
Cat. No. #H514ꢀ
Qty
(1) left log (B)
(1) right log (C)
(1) front log (D)
(2) log support brackets (E)
cut lines
C
B
Figure 31
Bracket correctly placed
D
E
E
Figure 30
Figure 32
Tools Required
None
B
C
CAUTION: The logs can be damaged if they are not handled
with care!
To Install the log set:
1. Remove the two log support brackets from the box and bend the ends
of the brackets 90 degrees at the cut lines. See Figure 31.
2. One bracket goes into the left corner and the other into the right corner
of the firebox. Rotate the brackets so they are placed as shown in
Figure 32. The bracket fits between the back of the firebox and the
air wash at the front of the insert.
D
Figure 33
3. Remove the ceramic logs from the box and carefully unwrap them.
Position each back log (Figure 33, B, C) in their proper place, one
on each side against the back of the firebox.
4. The front log should face the front of the firebox with the wood grain
showing. It should rest on the other two back logs. See Figure 33
for assembled log set.
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2. Push the start button and the ignite and feeding lights will come on
and the lighting sequence will begin. For about the next 15 minutes the
insert will feed pellets cyclically into the burn pot, the combustion fan
will come on, and the igniter will heat up. During this sequence, some
smoke in the firebox is to be expected. After the igniting sequence is
complete, the insert will begin burning at the level indicated by the
heat selector knob.
OPERATION
Control Board
The control board regulates all functions of the insert. The following is
a list of the board’s components:
Note: Upon the insert’s initial light up, or if the insert has previously run
out of pellets, the auger feed tube may not contain a sufficient number of
pellets to allow the insert to continue burning after the ignition sequence.
It may be necessary to push the start button a second time to run the start
sequence again. It is important to always empty (when cool) the burn pot
of pellets before pushing the start button a second time.
• Feeding light - lights up when the auger is feeding pellets into the
burn pot.
• Ready Light - lights up when insert is ready to operate.
Igniting Light - lights up when the insert is in the ignition sequence.
• Start Button - is pushed to start the ignition sequence after the heat
selector knob is turned from off.
Heat Selector Knob - is turned to off to shut the insert off or turned
to a setting from 1 to high to regulate the burn
rate.
WARNINGS
• Igniter Fuse - six amp fuse to protect igniter heating element.
• Control Fuse - three amp fuse to protect the control board.
•NeveremptypelletsfromtheBurn-Potintothehopper.
Pellets that may appear to be cool may retain enough
heat to ignite other pellets resulting in smoke or fire
damage.
Igniting Ready Feeding
Start
• DO NOT OVERFIRE THIS STOVE. This may cause
serious damage to your stove and void your warranty.
It also may create a fire hazard in your home. IF ANY
EXTERNAL PART OF THE UNIT BEGINS TO GLOW, YOU
ARE OVERFIRING. Immediately slide the knob to the
"OFF" position on the control board.
2
3
Manual Operation
4
High
1
After the insert is burning (see Lighting on this page), the heat selector
knob controls the pellet burn rate and the insert’s heat output. Turning the
knob to setting 1 allows the insert to burn about 1.8 pounds of pellets per
hour - about 8,500 BTUs per hour. Turning the knob to high allows the
inserttoburn4.7poundsofpelletsperhour-about39,000BTUsperhour.
Once set, the insert will continue to burn at this rate until shut off.
Off
Heat Selector
Knob
Thermostat Operation
Control Fuse
Igniter Fuse
This insert will operate with a low voltage thermostat. See Page 12 for
instructions on installing the thermostat. Once installed, the thermostat
will control the operation of the insert. Important: When connected to a
thermostat, it is necessary to push the ignite button for the initial burn,
when the electrical flow to the insert is interrupted, if the selector knob
is turned to off (and then back on), or if the insert runs out of pellets and
thereforeshutsoff.Aftertheinitialignitionsequence,whenthethermostat
calls for heat (the room temperature is less than the temperature set on
the thermostat) and the heat selector knob is not in the off position, the
insert will burn at the heat selector knob setting. The higher the setting,
the quicker the room will heat up. Once the thermostat no longer calls for
heat (the room is up to the desired temperature), the insert will continue
to burn for one additional hour at the lowest setting. If the thermostat
does not call for heat again during that hour, the insert will shut off. Dur-
ing that hour, if the thermostat calls for heat again, the insert will again
burn at the heat selector knob setting until the thermostat no longer
calls for heat. If the insert shuts off after that hour it will relight when
the thermostat calls for heat.
Figure 34
Filling the Hopper
The hopper can be accessed by lifting the lid at the rear of the top of the
insert. The hopper will hold 60 pounds of pellets. Remove any contents
from the hopper and fill with pellets.
Lighting
1. Turn the heat selector knob (see Figure 34) to the heat level desired
- 1 through high - and the ready light will turn green.
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Once you find a pellet brand that burns well, continue using this brand.
High ash fuel increases the frequency of insert cleaning. Fuel with an
excessive moisture content may jam the auger assembly.
Shut Down
Normal - To turn the insert off, turn the heat selector knob to off. The
fans will continue to operate until the control board completes the shut
down cycle.
Corn Fuel
Shelled corn can be burned in the Winslow PI40 insert when it is mixed
with wood pellet fuel (see Fuel Specifications on Page 5). The mixture
can contain a maximum of 50 percent corn. Burning corn may create
more ash than wood pellets and may necessitate the need to clean the
burn pot and glass more frequently.
PowerOutage-Iftheinsertloseselectricalpowerforlessthan10seconds
it will continue to operate. If the power loss is greater than 10 seconds,
the insert will go into the ignition sequence and normal operation when
the power is restored. If the insert is connected to a thermostat, the insert
will not start the ignition sequence until the thermostat calls for heat.
Paint Curing
CAUTIONS
This insert has been painted with a high temperature metallic paint. It
leaves the factory dry to the touch, but completes the curing process as
the insert is used. The paint will cure during the first few times the insert
is burned. Also some parts of the appliance may be lightly coated with
machining oil. Ventilate the house during these first firings as the paint
and oil give off carbon 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.
INSTALLATION AND REPAIR SHOULD ONLY BE PERFORMED
BY A QUALIFIED SERVICE TECHNICIAN. DO NOT ATTEMPT TO
SERVICE THE APPLIANCE YOURSELF.
Avoid overfiring the insert - do not hand feed pellets to the
appliance.
Never use gasoline, gasoline-type lantern fuel, kerosene,
charcoal lighter fluid, or similar liquids to start or fresh up a
fire in this heater. Keep all such liquids well away from the
heater while it is in use.
Convection Blower Operation
YourWinslow™PI40insertcomesequippedwithatemperatureactivated
convection blower that extracts heat from the insert. After the insert
warms up, a heat activated switch will turn the fan on. The speed of the
fan varies with the burn rate of the insert. The fan will continue to extract
heat after the insert shuts off and until it is cooled down.
For your safety, do not install or operate your Winslow PI40
insert without first reading and understanding this manual.
Any installation or operation of the appliance deviating from
that which is stated in this instruction manual WILL void the
warranty and may be hazardous.
Operating Sounds
As the Winslow PI40 insert is burning, a number of normal operational
sounds may be heard. Pellets can be heard sliding down the auger tube
and into the burn pot. Also, the motor powering the auger can be heard
as the control board calls for pellets. Occasionally a loud noise can be
heard as the auger cuts a pellet in half. When the blowers come on, the
sound of rushing air may be heard. The lower the burn rate the slower
the fan operates. Hourly, the combustion fan will blow at a high speed
to clean ash from the burn pot.
Due to high temperatures, the insert should be located out of
traffic areas and away from furniture and draperies. Children
and adults should be alerted to the hazards of high surface
temperature and should stay away to avoid burns or clothing
ignition. Young children should be carefully supervised when
they are in the same room as the Winslow PI40 insert. Clothing
oranyotherflammablematerialshouldnotbeplacedonornear
the insert. Any grill, panel, or glass removed for service MUST
be replaced prior to operating the insert.
Pellet Fuel
Pellet fuel is made from sawdust and scrap wood from many different
species of wood. Pellets are either 1/4” or 5/16” in diameter and vary
in length (see Fuel Specifications on Page 5). The Winslow PI40 insert
will burn either diameter pellets. Pellets made from hardwoods contain
more ash than those made from softwoods. Minerals from ash and sand
in the pellets form clinkers under the extreme temperatures in the burn
pot. Try burning various brands of pellets until you find one that burns
with minimum ash and clinkers.
Donotoperateappliancewiththeglassfrontremoved,cracked,
or broken. Replacement of the glass should be done by a quali-
fied service technician.
Lennox Hearth Products, its employees, or any of its represen-
tatives assume no responsibility for any damages caused by
an inoperable, inadequate, or unsafe condition as a result of
any improper operation, service, or installation procedures,
whether direct or indirect.
Theappliance, wheninstalled, mustbeelectricallygroundedin
accordancewithlocalcodesor,intheabsenceoflocalcodes,with
the National Electrical Code, ANSI/NFPA 70-latest edition.
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Reinstall the ash drawer by inserting the drawer in the insert and refas-
tening the left and right latches securely. Note that if the ash drawer
does not seal tightly to the insert, the control board may detect a leak
and shut the insert down.
CLEANING AND MAINTENANCE
Unplug and let the Winslow™ PI40 insert cool before performing any
maintenance or cleaning. Some brands of pellets produce more ash and
clinkers than others. Therefore the frequency of performing the follow-
ing cleaning procedures depends to a great degree on the quality of the
pellets burned. Not cleaning this unit will cause it to burn poorly and
will void your insert’s warranty.
High Side Of Burn Pot Goes
Toward Front Of Insert
Burn Pot Cleaning
The combustion fan comes on at high speed once an hour to blow the
byproducts of combustion out of the burn pot. However, the burn pot
should be cleaned more thoroughly after burning about 10 bags of pel-
lets. The burn pot has a number of holes in the bottom and sides that
provide combustion air to the pellets. The extreme temperatures in the
burn pot can cause the impurities in the pellets to form ash and clinkers.
When the insert is cool, open the front door and lift out the cast iron burn
pot. Scrape the inner bottom and sides of the pot with a screwdriver to
remove all ash and clinkers from these surfaces. Make sure all the holes
in the pot are open. Place the burn pot in the hole from which it was
removed. Make sure the high side of the pot is rotated toward the front
of the insert (see Figure 35). Push the burn pot down so surface A is
tight against the steel supporting the pot. Do not substitute any other
grate or pot for use in this insert.
A
Figure 35
Cleaning Glass
CAUTION: Do not open the front door when the fireplace insert
is hot. To open the door, follow the first two steps listed in Front
Door Removal on Page 23. Clean the glass using a soft cloth
or paper towel and a household glass cleaner or gas stove
window cleaner. A damp cloth with a small amount of ash from
the firebox can also be used to clean the glass.
Cleaning the Heat Exchanger
CAUTION: Do not operate the heat exchange scraper when the
insert is hot. Located at the center of the Grill on the top front of
the insert is a bent rod that is attached to a scraper on the heat
exchange tubes. To remove ash build-up and maintain efficient
heat extraction from the insert, this rod should be pulled in and
out at least weekly.
B
Cleaning the Flue Gas Passageways
Cleaning the flue gas passageways should be done at least once a year.
Burning high ash pellets may require this cleaning to be done more often.
Clean these passageways only when the insert and ash are cold, do not
start a fire in the vacuum cleaner by vacuuming up hot ash.
On each side of the insert there are two access covers (see B and C in
Figure 36) that can be removed by unscrewing the two 5/32” allen head
screws. Insert a cleaning brush in the openings to loosen any ash build-
up and use a vacuum cleaner to remove the loosened ash. Reinstall the
covers when cleaning is complete.
C
Figure 36
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Cleaning the Combustion Blower
Removing the Ash from the Firebox
To clean the combustion blower, unplug the insert from the power source
and remove the six nuts labeled A in the drawing to the right with an
11/32” wrench. After removing these nuts, the motor with fan attached
can be pulled from the fan housing. The fan blades and the fan housing
can be vacuumed once the motor is removed. When reinstalling the mo-
tor, a new gasket may need to be installed between the motor and the fan
housing. To complete the reinstallation, place the motor back on the fan
housing and reinstall the six nuts. Make sure the motor’s green ground
wire is secured under one of the nuts.
CAUTION: Do not remove the ash when the insert or ash is hot.
To remove the ash, swing open the left and right side doors and
open the front door. Vacuum or scoop out the ash on the bottom
and side of the firebox.
CAUTION: Disposal of ashes should be placed in a metal con-
tainer with a tight fitting lid. The closed container should be
placedonanon-combustiblefloorortheground,wellawayfrom
all combustibles materials, pending final disposal. If the ashes
are disposed of by burial in soil or otherwise locally dispersed,
they should be retained in the closed container until all cinders
have been thoroughly cooled.
Cleaning the Vent Pipe
Soot and Flyash: Formation and Need for Removal
The products of combustion will contain small particles of flyash. The
flyash will collect in the exhaust venting system and restrict the flow of
the flue gases. Incomplete combustion, such as occurs during start-up,
shutdown,orincorrectoperationoftheroomheaterwillleadtosomesoot
formation which will collect in the exhaust venting system. The exhaust
venting system should be inspected at least once every year to determine
if cleaning is necessary. Sweep the pipe as needed.
A
The insert has a clean-out box to which the flue pipe or flex pipe is at-
tached. Toaccesstheclean-outbox, removetherightsidesurroundpanel
and right door. Figure 37 shows the box in the upright position attached
to the flue fan. Figure 38 shows the box from the bottom, revealing the
latch securing the box door. Pull the latch down to open the box. When
the ash is cold, use a vacuum cleaner to remove the ash from the box.
Refasten the box door by rotating the latch handle up.
Required Cleaning Schedule After Number Of Bags Burned:
Burn Pot = 10 bags
Ash Drawer = 50 bags
Traps = 50 bags
Figure 37
Flue Fan = 100 bags
Blower = 100 bags
Top
Note: Cleaning schedule will vary depending on quality of pellets used.
Burning high ash pellets will require more frequent cleaning.
Rotate
Latch
Handle
Bottom
Figure 38
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Cleaning the Convection Blower
B
Tocleantheconvectionblower,removetheleftsidedoor(seethefollowing
page). Disconnecttheinsertpowercordfromtheelectricaloutlet. Loosen
the two screws (A in Figure 39) securing the blower to the blower duct.
Slide the blower toward the outside of the insert - disengaging it from the
blower duct. A vacuum can be used to remove any dust accumulation on
the blower’s blades or inside the blower duct. Caution should be used not
to damage the blower’s blades during cleaning. To reinstall the blower,
slide the blower back into the retaining lip B and retighten screws A.
Slide to the side to
remove.
A
Adjustable Hopper
The Winslow™ PI40 insert is shipped with the 55 pound hopper. With
the larger hopper installed, that part of the insert that slides into the
fireplace is 22-1/2” (572 mm) high. For installations in smaller fireboxes,
the hopper is adjustable down to a height of 19” (483 mm). To adjust the
hopper to its lowest height of 19” (483 mm), remove screws C around
the hopper lid and lift the lid off. Next, remove the screws D around the
hopper extension and remove the extension. Place the lid back over the
hopper and reinstall the screws securing the lid.
To adjust the hopper height between the maximum and the minimum,
remove screws D and slide the hopper extension (with lid attached) down
around the hopper bottom to the height desired. The extension can be
loweredatmost2-1/2”(64mm).Reinstalltheself-tappingscrewsthrough
the holes in the extension (creating new holes in the hopper bottom).
Figure 39
Proof of Fire Switch
This switch needs to be removed and cleaned after every
100 bags of fuel burned.
Hopper Extension
Cleaning Procedure:
1. UNPLUG STOVE!
2. Locate the switch on the combustion blower (see Figure
43).
3. Using a flat-head screwdriver, remove the 2 screws which
secures the switch to the blower housing.
4. Using a dry cloth, wipe off any flyash build-up on the
sensor portion of the switch.
D
5. Reinstall switch. Ensure wires are properly connected
to the switch and the connectors are not making contact
with the blower housing. Close side panel.
Hopper Lid
Note: Failure to clean the proof of fire switch when
needed may result in nuisance shut-downs because the
fly-ash build-up insulates heat from reaching the switch.
(Recommended Frequency of 1 year or after every 100
bags of fuel used)
C
Figure 40
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Front Door Opening and Removal
CAUTION: Do not open the front door when the insert is hot.
To remove the door, swing the left and right side doors A open. Pull
the front door handle B to the front and swing the front door open. Lift
the front door up and off the hinges as shown in Figure 41 (see C). To
reinstall the door repeat the steps in reverse order.
C
Side Door Removal
To remove the door,
1. Swing the door open
2. Lift the door up, and
3. Pull the bottom of the door out and down - pulling the top hinge pin
out of the retaining hole in the top hinge bracket.
A
To reinstall the door, slide the pin on the top of the door up and into the
hole in the upper hinge bracket. Slide the pin on the bottom of the door
into the hole in the pedestal base and rotate the door closed.
Front Door
B
Figure 41
ꢀ
Side
Door
1
3
Figure 42
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
ꢀ3
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COMPONENT INFORMATION
The following is a list of components and their functions.
Igniter
The Winslow™ PI40 insert comes equipped with an automatic igniter
for lighting the fuel when the insert is in the lighting mode. The igniter
superheats air that is pulled through the burn pot by the combustion
blower to light the fuel. The igniter remains energized for the first seven
minutes of the lighting sequence.
Vacuum Switch
TheWinslowPI40inserthasavacuumswitchlocatedbehindtheleftdoor,
fastened to the base (see A in Figure 44). If there is a leak in the firebox
created by the front door being ajar or a blocked flue, the vacuum switch
will sense it and cause the insert to go into a shutdown mode.
Auger and Auger Motor
Combustion
Blower
The 1.25 RPM auger motor (B in Figure 22) turns the auger lifting pellets
up the auger tube. The pellets are then dropped down a tube and into the
firepot. The auger is controlled by the control board.
Figure 43
Over Temperature Snap Switch
(Opensat225F)Thisswitchisinstalledontheconvectionblower(seeCin
Figure 44) and shuts the insert down if it senses excessive temperatures.
This snap switch has a reset button on it and will not allow the insert to
start up until the reset button has been pushed.
Proof of Fire Snap Switch
(Closes at 140° F) This switch is installed on the combustion blower and
shuts the insert down if it does not detect fire in the burn pot.
Convection Blower Snap Switch
(Closes at 120° F) This switch is installed on the right rear of the
firebox and turns the convection blower on when the insert gets up to
temperature.
B
C
A
Room Air
(Convection) Blower
Figure 44
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
ꢀ4
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Draft Adjuster
The Winslow™ PI40 insert has a draft adjuster located at the right side
of the insert directly in front of the combustion blower. Should the insert
installation require long runs of vent pipe, a situation may be created
where excessive combustion air is flowing through the firebox and caus-
ing the fuel to burn faster than it can be delivered to the burn pot. Should
this happen, the draft can be slowed down by the adjuster. The insert
is shipped with the adjuster in the fully open position. To slow the draft
down, loosen the 5/32” allen head screw (A in Figure 45) and move the
adjuster handle toward the center of the insert. Retighten the screw when
the desired adjustment is reached.
A
A
Draft Adjuster
d j u s t D
Wiring Diagram
Figure 45
10
YEL
9
8
7
6
RED WHT GRY
BRWN
1
VIOL
5
4
3
2
ORNG BLK GRN BLU
Molex 10 Pin Connector
ORANGE
BROWN
BLACK
RED
GRAY
GREEN
BLUE
VIOLET
YELLOW
BLOWER
SNAP SWITCH
IGNITER
PROOF OF
FIRE SNAP
SWITCH
OVER TEMP
SNAP SWITCH
ROOM AIR
(CONVECTION) BLOWER
BROWN
AUGER
MOTOR
VACUUM
SWITCH
COMBUSTION
BLOWER
BUS
WHITE
WHITE
WHITE
BLACK
GREEN
GROUND
Figure 46
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
ꢀ5
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DIAGNOSTIC CODES
If the insert operates abnormally, the ready light on the control board will signal the nature of the abnormal operation. The following is a list of pos-
sible signals or codes:
Ready light is constant red
Ignition Failure
Vacuum Switch Open
Proof of Fire Snap Switch Open
Over Temperature Snap Switch Open
Ready light flashes red 1 short and 1 long blink
Ready light flashes red ꢀ short blinks
Ready light flashes red ꢀ long blinks
Troubleshooting
Ignition Failure - Code - Ready light is constant red and ignite light flashes two short blinks
Possible Problem Solution
Hopper is out of pellets
Auger tube was not full of pellets when start button was pushed When cool, empty pellets in burn pot and push start button again
Fill the hopper with pellets
Burn pot dirty - holes plugged
Igniter not functioning
Igniter fuse blown
Clean the burn pot
Replace the igniter
Replace 6 amp fuse located on front of the control board
Control Board has no Power - When selector knob is turned no lights light up
Possible Problem Solution
Power cord is not plugged in
Board fuse blown
Plug in power cord
Replace 3 amp fuse located on front of control board
Check circuit breaker panel
Wall outlet not energized
Board broken, damaged, or defective
Replace the control board
Vacuum Switch Shuts Insert Down - Code - Ready light flashes red 1 short and 1 long blink
Possible Problem
Front door is not sealing
Solution
Latch or adjust the front door or replace door gasket
Close latches, adjust latches, or replace drawer gaskets
Clean the passageways (see Page 20)
Clean the vent pipe (see Page 21)
Ash drawer is not sealing
Flue gas passageways restricted
Vent pipe restricted
Vacuum hose plugged
Clean or replace the vacuum hose
Vacuum switch defective
Replace the vacuum switch
Proof of Fire Snap Switch Shuts Insert Down - Code - Ready light flashes red 2 short blinks
Possible Problem Solution
Hopper is out of pellets
Auger tube was not full of pellets when start button was pushed When cool, empty pellets in burn pot and push start button again
Fill the hopper with pellets
Snap switch* defective
Replace the snap switch
“Proof of fire” switch is dirty
Clean switch per instructions on Page 22
ꢀ6
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Over Temperature Snap Switch Shuts Insert Down - Code - Ready light flashes red 2 long blinks
Possible Problem
Convection blower not running
Solution
Blower dirty, blower snap switch bad, or blower broken
Clean passageways or vent pipe (see Pages 20 and 21)
Replace the snap switch*
Flue passageways or vent restricted
Snap switch* defective
* Note: The snap switch has a reset button that must be pushed before insert will function (see Page 24).
Orange Sooty Flames - Glass turns Black
Possible Problem
Solution
Burn pot is dirty
Clean the burn pot
Clean the vent pipe
Clean the passageways
Vent pipe restricted
Flue gas passageways restricted
Combustion blower dirty
Burning improper fuel
Clean the combustion blower
Burn only wood pellet fuel or corn fuel that meets the fuel speci-
fications outlined on Page 5
Pellets not Feeding
Possible Problem
Solution
Hopper empty
Fill the hopper
Auger jammed
Call service technician
Call service technician
Call service technician
Flue gas passageways restricted
Auger motor not operating
REPLACEMENT PARTS
Contact an Authorized Lennox Hearth Products dealer to obtain any of these parts. Never use substitute materials. Use of non-
approved parts can result in poor performance and safety hazards.
H5984
H3112
79040
H6021
H5988
H5911
79021
H6005
H5891
H6004
H5887
H3128
H6020
H5898
H5889
H5976
70K99
Decorative Nickel Bars / Upper Body
Door Handle Assembly
Door w/glass (No Trim)
Flue Clean Out Box
Hardware Package
Hopper Door Wire
Igniter Fuse 6 Amp, 5 Pack
Igniter W/hose Clamp
Overtemp Switch
Power Cord
Proof Of Fire Switch
Right Flange W/controls Access Door 40”
Right Flange W/controls Access Door 48”
Vacuum Line 12” Piece
Vacuum Switch
Wiring Harness
Touch-Up Paint, Black
Winslow™ PI40 insert
Cat. No.
H6006
H3111
H5886
H5921
H5875
H5856
H5899
H6019
H5900
H5903
H5917
H5978
79020
H5888
H5902
Description
Adjustable Latch Pin
Ash Clean Out Cover, 2 Per Insert
Auger Motor
Auger w/lower Bearing
Blower Snap Switch
Cast Burn Pot
Clean-out Cover Gasket
Combustion Blower
Combustion Gasket Housing To Insert
Combustion Gasket Motor To Housing
Control Board Access Latch
Control Board
Control Board Fuse 3 Amp, 5 Pack
Convection Blower
Convection Blower Gasket
ꢀ7
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Zero Clearance Kit
Description
ACCESSORIES
Cat. No.
790ꢀ5
Model
PI40-ZCK
Zero Clearance Kit
Surround Panel Kits (required - sold separately)
Cat. No.
79004
79005
79006
79007
H7ꢀ3ꢀ
Model
Description
Pellet Heat Kits
PI40-FPKꢀ941
PI40-FPKꢀ948
PI40-FPK3341
PI40-FPK3348
PI40-3ꢀZCFK
ꢀ9” Ht. x 41” Wd. Black Trim
ꢀ9” Ht. x 48” Wd. Black Trim
33” Ht. x 41” Wd. Black Trim
33” Ht. x 48” Wd. Black Trim
ꢀ9” Ht. x 41” Wd. 3” Deep *
790ꢀ4
790ꢀ6
790ꢀ7
790ꢀ8
790ꢀ9
75ꢀ51
7506ꢀ
75063
PI40-HK
Pellet Heat Kit
PI40-HK30411
PI40-HK3048F
30-5/8” Ht. x 41” Wd. Surround Panels
30-5/8” Ht. x 48” Wd. Surround Panels
PI40-HK3441F41 34-5/8” Ht. x 41” Wd. Surround Panels
PI40-HK3448F
GFHKET-B
34-5/8” Ht. x 48” Wd. Surround Panels
Extended Side Trim Kit, Black
*ThethreeinchdeepsurroundassemblypositionstheWinslow™pelletinsertthreeinches
forward onto the hearth which allows the insert to fit into a fireplace with a narrower front
width (32” minimum). Using the other standard surround sizes require a minimum front
fireplace width of 36”.
GFHKET-G
GFHKET-N
ZC Front Support Extension Trim, Gold
ZC Front Support Extension Trim, Nickel
Door Trim (required - sold separately)
79038
79034
79037
79035
79036
P40DT-B
P40DT-G
Black
Common Accessories
Gold
79003
H514ꢀ
79030
H6907
70005
PI40FS
P40LOG
Front Support 41-48” Width/0-8” Height
Log Set
P40DT-N
Nickel
P40DT-BRN
P40DT-BLN
Brushed Nickel
Black Nickel
P40BRICK
P40DIAG40
RT-AC
Standard Brick Panel
Diagnostic Tool
Remote Control w/Thermostat, Alternating
Current
Grill Finish
Black
H0ꢀ51
RCL-STAT
Deluxe Remote Control
(Timer, Thermostat, Clock)
79000
79001
7900ꢀ
790ꢀꢀ
79039
P40G-B
P40G-G
Gold
H4635
70K99
DWTK
Digital Wall Thermostat Kit
P40G-N
Nickel
TSPK-B
Touch-up Spray Paint Kit, Black
P40G-BN
P40G-BLN
Brushed Nickel
Black Nickel
Surround Trim
H5143
H5145
H5144
H5146
75036
75038
75040
7504ꢀ
75037
75039
75041
75043
GFTꢀ941-B
GFTꢀ948-B
GFT3341-B
GFT3348-B
GFTꢀ941-G
GFTꢀ948-G
GFT3341-G
GFT3348-G
GFTꢀ941-N
GFTꢀ948-N
GFT3341-N
GFT3348-N
Trim/Black ꢀ9” Ht. x 41” Wd.
Trim/Black ꢀ9” Ht. x 48” Wd.
Trim/Black 33” Ht. x 41” Wd.
Trim/Black 33” Ht. x 48” Wd.
Trim/Gold ꢀ9” Ht. x 41” Wd.
Trim/Gold ꢀ9” Ht. x 48” Wd.
Trim/Gold 33” Ht. x 41” Wd.
Trim/Gold 33” Ht. x 48” Wd.
Trim/Nickel ꢀ9” Ht. x 41” Wd.
Trim/Nickel ꢀ9” Ht. x 48” Wd.
Trim/Nickel 33” Ht. x 41” Wd.
Trim/Nickel 33” Ht. x 48” Wd.
ꢀ8
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Heat Kit Instructions
Kit Contents
(Refer to Figure 47)
1 ea. 2” lower trim piece (A)
1 ea. 1” insulated micro board (B)
2 ea. 1/2” x 10-24” screws (C)
Tools Required
5/32 allen wrench
Remove
1. Install the 2” lower trim piece. Fasten the 2” trim piece underneath
the base of the front of the insert using the 2 screws (see C in Figure
47) provided, one at the left side and one at the right side base of the
insert. Note: This process will be simplified by very cautiously tilting
the insert back (see Figure 48).
Figure 49
2. Install your 4 leveling bolts. Open the main front door and remove the
2 bolts in the front right and front left of the bottom of the fire box see
Figure 49. Note: Placing a level on the insert top is recommended to
ensure your insert is level. Again with the insert very cautiously tilted
back insert your 4 leveling bolts approximately 2-1/16” (52 mm) into
the holes provided at the bottom of the insert (see Figure 50).
3. Setinsertonmicroboard. Nowthattheinsertislevel, placeyourmicro
board in place where the insert will be installed and set the Winslow
PI40 insert over the micro board so the 2 front leveling legs line up
with the two cut-outs in the front of the micro board see Figure 51.
Your Winslow PI40 insert heat kit is now installed.
A
Figure 50
B
C
Figure 47
Figure 51
Figure 48
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
ꢀ9
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Pellet Insert ZC Kit Assembly
Kit Contents
B
C
(refer to Figure 52)
A
1 ea. Back panel (A)
R
1 ea. Left side panel (B)
1 ea. Right side panel (C)
1 ea. Top panel (D)
G
1 ea. Access panel (E)
F
D
T
H
1 ea. Flue block off plate (F)
6 ea. Standoff brackets (G)
2 ea. Rubber grommets (H)
26 ea. 1/8 x 1/2 inch screws (I)
4 ea. Door washers (J)
1 ea. Rear vent adapter (K)
I
E
J
K
Figure 52
Tools Required
1/4” Nut Driver, 1/8” Drill
Installation Instructions
K
Note: Top or rear vent? If you will be venting out the top then you will
install the block off plate F onto the lower back panel A in the spot that
is marked R in Figure 52. If you are venting out the back you will install
the block off plate F onto the top panel D in the spot that is marked T in
Figure 52. You will use four of the sheet metal screws provided to attach
the block off plate, part F.
1. In a rear vent termination you will have to remove the three screws
(one on top and one on each the right and left side) that hold on the
flue clean out box and replace it with the adapter (shown in Figure 53).
Make sure the flat edge is directed towards the inside of the insert.
(Figure 54).
Figure 53
K
Figure 54
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
30
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4. Installing the standoffs, parts G. There are 3 standoffs on the top
panel D (see Figure 57). Insert them by taking the lip of the standoff
and sliding them into the slots then push down. Using a sheet metal
screw provided screw them into the hole provided. There is also one
standoff on each the right, left and the back panel. Showing standoff
on left panel C in Figure 58.
2. Assembling the perimeter - Figure 55: Using the sheet metal screws
provided, attach the left side panel B and the right side panel C to the
back panel A. There are 3 holes at each corner to connect the panels,
at this point only install the lower two screws at each corner.
A
B
C
D
Figure 55
3. Install the top panel D. Place panel D on top of panels A, B, and C as
shown in Figure 56. There are 3 holes across the top of the panel
on each side. Insert the screws only on the right and left side. The 3
remaining holes in panel D will be used in step five.
Figure 57
E
D
C
Figure 58
Figure 56
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
31
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5. Now remove the 3 screws located across the top of the pellet hopper.
(See Figure 59). At this time set the assembled ZC box near the back
of the insert and take the power cord located in the lower rear of the
insert and pull it through the rubber grommet located at the bottom
of the back panel A. Then on the right panel C, pull the wiring harness
through the rubber grommet located towards the bottom Figure 60.
Slide the ZC box snug up against the back of the insert and reinstall
the 3 screws previously removed through the ZC box and into the
insert (three holes shown in Figure 59).
C
E
Figure 61
7. Final step: Using the four oblong washers and 4 sheet metal screws,
insert two on each lower side of your ZC box shown in Figure 62. You
are now ready to install your pellet insert. Follow all vent clearances
stated in the installation and operation manual.
Figure 59
Figure 62
Figure 60
6. Installing access panel: Taking the access panel (E in Figure 61) and
4 of the sheet metal screws provided, screw the access panel E onto
the right side panel C as shown in Figure 61).
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
3ꢀ
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ZC Framing Dimensions for Combustible /Floor
Top View
Exhaust
8-1/4”
(ꢀ10mm)
9-1/8”
Front
(ꢀ3ꢀmm)
39”
(991mm)
Front View
Exhaust
A/C
Power Cord
Intake
6-3/4”
(17ꢀmm)
4”(10ꢀmm)
3-1/ꢀ”(89mm)
3-1/2”
10-3/8”
(ꢀ64mm)
19-1/ꢀ”
(495mm)
ꢀ5-1/ꢀ”
(648mm)
Side View
Outside Air Intake
ꢀ9-1/ꢀ”
(749mm)
A/C Power
Exhaust
16-1/8”
(410mm)
Figure 63
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
33
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ZC Framing Dimensions for Non-Combustible Hearth /Floor
Top View
Exhaust
8-1/4”
(ꢀ10mm)
9-1/8”
Front
(ꢀ3ꢀmm)
39”
(991mm)
Front View
Exhaust
Intake
A/C Power Cord
4-3/4”
(1ꢀ1mm)
3”(76mm)
ꢀ-1/ꢀ”(64mm)
-1/”
10-3/8”
1
(ꢀ64mm)
19-1/ꢀ”
Side View
(495mm)
ꢀ5-1/ꢀ”
(648mm)
Outside Air Intake
ꢀ8”
(711mm)
A/C Power
Exhaust
16-1/8”
(410mm)
Figure 64
NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
34
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NOTES
35
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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 pellet insert 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.
3. The Cat. No..
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 27 for a complete replacement parts list. Use only parts sup-
plied from the manufacturer.
Your Insert’s Model Number __________________________________________
Your Insert’s Serial Number___________________________________________
The Date On Which Your Insert Was Installed _____________________________
Your Dealer's Name _________________________________________________
Your Dealer's Phone Number__________________________________________
Lennox Hearth Products 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. © ꢀ007 Lennox Hearth Products
P/N 775,ꢀꢀ9M REV. B 08/ꢀ008
1110 West Taft Avenue • Orange, CA 9ꢀ865
36
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