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Duluth Forge FDF400T-ZC Series, Owner'S Operation And Installation Manual

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Duluth Forge FDF400T-ZC Series Owner'S Operation And Installation Manual Download Page 21

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21

200373-01A

INSPECTING BURNERS

IMPORTANT: Owner’s should check pilot flame pattern and burner flame pattern often. 

Incorrect flame patterns indicate the need for cleaning (see Care and Maintenance, 

page 22) or service.

 WARNING: Only a qualified service person should service and 

repair heater. This includes maintenance requiring replacement or 

alteration of components.

PILOT FLAME PATTERN

Figure 23 shows a correct pilot flame pattern. 

Figure 24 shows an incorrect pilot flame pat-

tern. The incorrect pilot flame is not touching 

the  thermocouple. This  will  cause  the  ther-

mocouple to cool, which shuts the heater off.
If pilot flame pattern is incorrect, as shown 

in Figure 24
•  turn heater off (see 

To Turn Off Gas to Ap-

pliance

, page 20)

•  see 

Troubleshooting

 pages 24 through 27.

 WARNING: If yellow tipping 

occurs, your heater could pro-

duce increased levels of carbon 

monoxide.  If  the  burner  flame 

pattern  shows  yellow  tipping, 

follow instructions at bottom of 

this page.

Notice: Do not mistake orange flames with 

yellow tipping. Dirt or other fine particles enter 

the heater and burn causing brief patches of 

orange flame.

Approx. 3"-6" Above Top of Logs

More Than 8" Above Top of Logs

Approx. 3"-6" Above Top of Logs

More Than 8" Above Top of Logs

Figure 25 - Correct Burner Flame Pattern

Figure 26 - Incorrect Burner Flame 

Pattern

BURNER FLAME PATTERN

Figure 25 shows a correct burner flame pattern. Figure 26 shows an incorrect burner flame 

pattern. If burner flame pattern is incorrect then:
•  turn heater off (see 

To Turn Off Gas to Appliance

, page 20).

•  see 

Troubleshooting

 pages 24 through 27.

BURNER PRIMARY AIR HOLES

Air is drawn into the burner through the holes in the fitting at the entrance to the burner. These 

holes may become blocked with dust or lint. Periodically inspect these holes for any blockage 

and clean as necessary. Blocked air holes will create soot.

Figure 23 - Correct Pilot Flame Pattern 

(Natural Gas shown)

Figure 24 - Incorrect Pilot Flame Pattern 

(Natural Gas shown)

NG

3-3.5" WC

Natural Gas

Shown

LP

8-11" WC

NG

3-3.5" WC

Natural Gas

Shown

LP

8-11" WC

Summary of Contents for FDF400T-ZC Series

Page 1: ... switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a quali fied installer service agency or the gas supplier WARNING Thisappliance isequippedfornatural and propane LP gas Field conversion is not per...

Page 2: ...roper installation adjustment al teration service or maintenance can cause injury or property damage Refer to this manual for correct in stallation and operational procedures For assistance or additional information consult a qualified installer service agency or the gas supplier This appliance may be installed in an aftermarket per manently located manufactured mobile home where not prohibited by...

Page 3: ...rate or service this heater Improper use of this heater can cause serious injury or death from burns fire explosion electrical shock and carbon monoxide poisoning Failure to follow these instructions will void the warranty Onlyaqualifiedinstaller service agent or local gas supplier may install and service this product WARNING Keep the appli ance area clear and free from combustiblematerials gasoli...

Page 4: ...part has been under water Immediately call a qualified service technician to inspect the room heater and to replace any part of the control system and any gas control which has been under water SAFETY 10 Turn off and unplug heater and let cool before servicing Only a qualified service person should service and repair heater 11 Operating heater above elevations of 4 500 feet could cause pilot outag...

Page 5: ...sh air PIEZO IGNITION SYSTEM This heater is equipped with an electronic piezo control system This system requires AAA batteries provided THERMOSTAT HEAT CONTROL The control automatically cycles the burner on and off to maintain a desired room tem perature 2 GAS OPTIONS AVAILABLE Your heater is equipped to operate on either Propane LP or Natural gas The heater is shipped from the factory ready for ...

Page 6: ...monwealth of Mas sachusetts Sellers of unvented propane or natural gas fired supplemental room heaters shall provide to each purchaser a copy of 527 CMR 30 upon sale of the unit In the State of Massachusetts the gas cock must be a T handle type The State of Massachusetts requires that a flexible appliance connector cannot exceed three feet in length 1 Remove top inner pack 2 Tilt carton so that he...

Page 7: ...eproperfresh air for this and other fuel burning appliances in your home Today s homes are built more energy efficient than ever New materials increased insulation and new construction methods help reduce heat loss in homes Home owners weather strip and caulk around windows and doors to keep the cold air out and the warm air in During heating months home owners want their homes as airtight as poss...

Page 8: ...oor into adjoining room see option 3 Figure 2 Follow the National Fuel Gas Code ANSI Z223 1 NFPA 54 Air for Combustion and Ventilation for required size of ventilation grills or ducts Ventilation Air From Outdoors Provide extra fresh air by using ventilation grills or ducts You must provide two perma nent openings one within 12 of the ceiling and one within 12 of the floor Connect these items dire...

Page 9: ...ents or ash clean out doors located on floor or wall of fire place If not drafting may cause pilot outage or sooting Use a heat resistant sealant Do not seal chimney flue damper WARNING Never install the heater in a bedroom or bathroom in a recreational vehicle where curtains furniture clothing or other flammable objects are less than 42 from the front top or sides of the heater in high traffic ar...

Page 10: ...prohibited CAUTION To avoid gas leak age for the gas not being used at the inlet of regulator a qualified installer or service technician must use supplied cap You will notice a color coded plungerontheinsideoftheregula tor Thisisnormal Whentheinlet connection fitting is inserted and tightened this plunger will be pushed back by the fitting making all of the adjustments for the gas being supplied ...

Page 11: ...ack as the fitting is installed Make sure the type of gas being used is correct Check to make sure the connection fitting is in the correct inlet on the regula tor Refer to Connecting to Gas Supply page 14 If you are using natural gas and the pilot will not light see Troubleshooting page 24 Metal Cap Metal Cap DO NOT REMOVE Yellow Natural Gas Plunger Install Gas Fitting Here 2 Apply thread sealant...

Page 12: ...wall should not be less than 12 see Figure5 B Clearance from the top of the fireplace to the ceiling must not be less than 48 BUILT IN FIREPLACE INSTALLATION WARNING Do not allow any combustiblematerialstooverlap the firebox front WARNING Do not allow combustibleornoncombustible materialstocoveranynecessary openings like louvered slots WARNING Never modify or cover the louvered slots on the front ...

Page 13: ...ocate standoff brackets in the hardware bag Remove screws from the top of the firebox Install brackets with screws as shown in Figure 10 3 Carefully set fireplace in front of rough opening with back of fireplace inside wall opening 4 Attach gas line to fireplace gas regulator See Connecting to Gas Supply page 14 5 Check all gas connections for leaks See Checking Gas Connections page 16 27 5 8 26 7...

Page 14: ... acceptable al ternative to test gauge connection Purchase the optional CSA design certified equipment shutoff valve from your dealer WARNING A qualified ser vice technician must connect heater to gas supply Follow all local codes WARNING This appliance requires a 3 8 NPT National Pipe Thread inlet connection to the pressure regulator WARNING Do not over tighten gas connections WARNING For natural...

Page 15: ...nting Down External Regulator with Vent Pointing Down Propane LP Supply Tank Equipment Shutoff Valve Ground Joint Union 3 8 NPT Pipe Nipple Tee Joint Reducer Bushing to 1 8 NPT 1 8 NPT Plug Tap Test Gauge Connection Sediment Trap Tee Joint Pipe Nipple Gap 3 Minimum reduce incoming gas pressure to between 11 and 14 of water If you do not reduce incoming gas pressure heater regulator damage could oc...

Page 16: ...PING SYSTEM Test Pressures In Excess Of 1 2 PSIG 3 5 kPa 1 Disconnect heater with its appliance main gas valve control valve and equipment shutoff valve from gas supply piping sys tem Pressures in excess of 1 2 PSIG will damage heater regulator 2 Cap off open end of gas pipe where equip ment shutoff valve was connected 3 Pressurize supply piping system by either opening propane LP supply tank valv...

Page 17: ... It is very important to install the logs exactly as instructed Do not modify logs Use only logs supplied with heater Each log is marked with a number This number will help you to identify the logs when installing After installing logs add decorative cinders around the grate base do not place any decorative cinders on logs or burner 1 Install pins on log 1 into the two slots in the bracket attache...

Page 18: ...product For long periods of non operation remove batteries from all components for safety Unscrew ignitor cap and install a AAA battery with the pointing out Replace cap Figure 20 Installing Battery in Ignitor AAA Battery Positive UP 4 Install pins on log 4 onto the two slots in the front bracket see Figure 16 and Figure 18 5 Insert the recessed hole on the bottom of log 5 onto the pin on log 2 se...

Page 19: ...s been under water FOR YOUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS WARNING You must oper ate this heater with the screen in place Make sure screen is installed before running heater NOTICE Duringinitialoperationof new heater burning logs will give offapaper burningsmell Orange flame will also be present Open damper or window to vent smell This will only last a few hours 1 STOP Read the ...

Page 20: ...ore starting again 10 Make sure heater screen is in place before operating heater 11 If heater will not operate follow the in structions To Turn Off Gas To Appliance and call your service technical or gas supplier CAUTION Do not try to ad just heating levels by using the equipment shutoff valve WARNING If input gas type is NG make sure NG pilot burner ignites If input gas type is LP make sure LP p...

Page 21: ...w tipping follow instructions at bottom of this page Notice Do not mistake orange flames with yellow tipping Dirt or other fine particles enter the heater and burn causing brief patches of orange flame Approx 3 6 Above Top of Logs More Than 8 Above Top of Logs Approx 3 6 Above Top of Logs More Than 8 Above Top of Logs Figure 25 Correct Burner Flame Pattern Figure 26 Incorrect Burner Flame Pattern ...

Page 22: ...ust dirt lint or pet hair with a soft cloth or vacuum cleaner nozzle 5 Blow air into the primary air holes on the injector holder 6 In case any large clumps of dust have now been pushed into the burner Repeat steps 3 and 4 CARE AND MAINTENANCE WARNING Turn off heater and let cool before servicing CAUTION You must keep control areas burner and circulating airpassagewaysofheaterclean Inspecttheseare...

Page 23: ...ow air through the air inlet hole You may blow through a drinking straw if compressed air is not available CABINET ODS PILOT Air Passageways Use a vacuum cleaner or pressurized air to clean Exterior Use a soft cloth dampened with a mild soap and water mixture Wipe the cabinet to remove dust CARE AND MAINTENANCE Figure 28 Pilot Inlet Air Hole LOGS If you remove logs for cleaning refer to Installing...

Page 24: ...C Bypass pressure switch See instructions below The entire gas delivery piping including con nections inside the heater should be leak tested by the qualified installer After leak testing the qualified installer should light the appliance Refer to the correct flame pattern as illustrated on page 21 All flame patterns should be safely inside the product If for any reason they are not stop use of th...

Page 25: ...e 2 Fully press in control knob while pressing ignitor button 3 Continue holding down con trol knob Repeat igniting op eration until air is removed 4 Clean ODS pilot see Care and Maintenance page 22 or replace ODS pilot assembly 5 Check inlet gas pressure or replace inlet gas regulator 6 Turn control knob to PILOT position 7 Contact local propane LP gas company ODS pilotlightsbutflame goes out whe...

Page 26: ...gas pressure is too low 1 Check burner for dirt and debris If found clean burner see Care and Maintenance page 22 2 Replace gas regulator 3 Contact local gas supplier Gas odor during com bustion 1 Foreign matter between control valve and burner 2 Gas leak See Warning Statement at top of page 24 1 Contact a qualified service technician to remove foreign matter 2 Locate and correct all leaks see Che...

Page 27: ...t page 24 2 Gas leak See Warning State ment at the top of page 24 3 Low fuel supply 1 Open a window to ventilate room Stop using odor caus ing products while heater is running 2 Locate and correct all leaks see Checking Gas Connec tions page 16 3 Refill supply tank Propane LP models Heater shuts off in use ODS operates 1 Not enough fresh air is avail able 2 Low line pressure 3 ODS pilot is partial...

Page 28: ...www factorybuysdirect com 200373 01A 28 PARTS MODEL FDF400T ZC 9 8 10 12 11 13 15 16 14 6 1 2 3 4 7 5 17 ...

Page 29: ...ower Louver 1 3 161368 01HT Left Door Assembly 1 4 161369 01HT Right Door Assembly 1 5 161139 03 ODS Pilot 1 6 Regulator 1 7 161338 01 Ignitor 1 161371 01 Log Set 1 8 HL041 01 Log 1 1 9 HL042 01 Log 2 1 10 HL043 01 Log 3 1 11 HL044 01 Log 4 1 12 HL045 01 Log 5 1 13 HL045 02 Log 6 1 14 ML073 04 Ignitor Cable 2 15 161383 01 Blower Access Panel 1 16 161130 01 Control Valve 1 17 161438 01 Offset Brack...

Page 30: ...site www factorybuysdirect com or give us a call at 1 855 607 6557 EQUIPMENT SHUTOFF VALVE For all models Equipment shutoff valve with 1 8 NPT tap Model and serial number of your heater How heater was malfunctioning Type of gas used Propane LP or Natural gas NG Purchase date Usually we will ask you to return the defec tive part to the factory PARTS NOT UNDER WARRANTY Contact authorized dealers of ...

Page 31: ...cified heat propane LP gas supply might be low propane LP units only You may feel your gas pressure is too low If so contact your local gas supplier TECHNICAL SERVICE You may have further questions about installation operation or troubleshooting If so contact Factory Buys Direct at 1 855 607 6557 When calling please have your model and serial numbers of your heater ready ...

Page 32: ...ost of part s required to restore this product to proper operating condition and an allowance for labor when provided by a Factory Buys Direct Authorized Service Center or a provider ap proved by Factory Buys Direct Warranty parts must be obtained through authorized dealers of this product and or Factory Buys Direct who will provide original factory replacement parts Failure to use original factor...

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