HEATILATOR CD4236IR (01) PDF Document

If you smell gas, follow these instructions immediately:

• Do not try to light any appliance.

• Do not touch any electrical 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.

HOT SURFACES! Glass and other surfaces are hot during operation and cool down. Hot glass will cause burns.

• Do not touch glass until it is cooled.

• NEVER allow children to touch glass.

• Keep children away.

• CAREFULLY SUPERVISE children in the same room as the appliance.

• Alert children and adults to the hazards of high temperatures.

High temperatures may ignite clothing or other flammable materials. Keep clothing, furniture, draperies, and other combustibles away. The appliance has an integral barrier to prevent direct contact with the fixed glass panel; do NOT operate the appliance with the barrier removed.

If you expect that small children or vulnerable adults may come into contact with this fireplace, the following precautions are recommended:

• Install a physical barrier such as a decorative firescreen or an adjustable safety gate.

• Install a switch lock or a wall/remote control with a child protection lockout feature.

• Keep remote controls out of reach of children.

• Never leave children alone near a hot fireplace, whether it is operating or cooling down.

• Teach children to NEVER touch the fireplace.

• Consider not using the fireplace when children will be present.

To prevent unintended operation when not using your HEATILATOR CD4236IR for an extended period of time (e.g., summer months, vacations):

• Remove batteries from remote controls.

• Turn off wall controls.

• For IPI models, unplug the 3-volt adapter plug and remove batteries.

• For standing pilot models, turn off the gas controls valve.

Before operating your HEATILATOR CD4236IR for the first time, have a qualified service technician perform the following checks:

• Verify all shipping materials have been removed from inside and/or underneath the firebox.

• Review proper placement of logs, rockwool, and/or other decorative materials.

• Check the wiring.

• Check the air shutter adjustment.

• Ensure that there are no gas leaks.

• Ensure that the glass is sealed and in the proper position and that the integral barrier is in place.

The IPI system automatically lights the pilot. Do not try to light the pilot by hand.

1. STOP! Read the safety information first. Smell all around the appliance area for gas. If you smell gas, follow the safety instructions provided.

2. To turn on the burner, turn on all electric power to the appliance and turn on the wall switch or set the thermostat to the desired setting.

3. If the appliance will not operate, follow the instructions “TO TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.

1. Turn off the wall switch or set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Push the gas control lever in and move to the “OFF” position or push the gas control lever to the “OFF” position. Do not force.

4. Replace the control access panel.

This appliance has a pilot which must be lit by hand. When lighting the pilot, follow these instructions exactly.

1. Turn wall switch to the “OFF” position or thermostat to the lowest setting.

2. Remove control access panel.

3. Turn manual gas valve to CLOSED. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow the safety information. If you don’t smell gas, go to the next step.

4. Turn gas line to “OPEN”.

5. Turn pilot knob clockwise to “OFF”. (The knob may have to be depressed to pass the “PILOT” position.)

6. Locate the pilot assembly inside the appliance.

7. Locate the red ignitor button.

8. Turn pilot knob to “PILOT” and push in.

9. Continue to hold in the pilot knob and push the red ignitor button 12-15 times until a small blue pilot flame appears.

10. Continue to hold in the pilot knob for approximately one minute. The pilot should remain lit. If the pilot goes out, wait 5 minutes and repeat Steps 3-9.

11. Release and turn knob counterclockwise to “ON”.

12. If the appliance will not operate, follow the instructions “TO TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.

NOTE: To light the main burner, turn the wall switch to “ON”. Do not light by hand.

1. Turn off the wall switch or set the thermostat to the lowest setting.

2. Remove the control access panel.

3. Turn the manual gas valve to the “CLOSED” position. Do not force.

4. Replace the control access panel.

The break-in procedure cures the materials used to manufacture the fireplace. You should open windows for air circulation during this process, as some people may be sensitive to smoke and odors, and smoke detectors may activate.

1. The fireplace should be run for three to four hours continuously on high.

2. Turn the fireplace off and allow it to cool completely.

3. Remove the fixed glass assembly and clean it.

4. Replace the fixed glass assembly and run continuously on high for an additional 12 hours.

Some appliances come equipped with a high/low flame adjustment control.

1. Open the control access panel.

2. Locate the gas valve and the flame adjustment knob (labeled with LO and HI).

3. Adjust the flame by turning the knob as indicated to your desired setting.

This is a normal result of gas combustion and temperature variations. As the HEATILATOR CD4236IR warms, this condensation will disappear.

This is a result of normal operation. The flames will begin to turn yellow as the HEATILATOR CD4236IR is allowed to burn for 20 to 40 minutes.

When first operated, the HEATILATOR CD4236IR may release an odor for the first several hours. This is caused by the curing of materials from manufacturing. Odor may also be released from finishing materials and adhesives used near the appliance. These circumstances may require additional curing related to the installation environment.

This is a normal result of the curing process of the paint and logs. The glass should be cleaned within 3 to 4 hours of initial burning. A non-abrasive cleaner such as gas appliance glass cleaner may be necessary.

This noise is caused by metal expanding and contracting as it heats up and cools down, similar to the sound produced by a furnace or heating duct. This noise does not affect the operation or longevity of the appliance.

For an Intellifire ignition system (IPI), the pilot flame should turn off when the appliance is turned off. Some optional control systems available with IPI models may allow the pilot flame to remain lit.

For a standing pilot system, the pilot will always stay on.

CAUTION! Risk of Burns! The fireplace should be turned off and cooled before servicing. Handle fixed glass assembly with care as glass is breakable.

• Avoid striking, scratching, or slamming the glass.

• Avoid abrasive cleaners.

• DO NOT clean glass while it is hot.

• Prepare a work area large enough to accommodate the fixed glass assembly by placing a drop cloth on a flat, stable surface.

• Remove the door or decorative front from the fireplace.

• See Section 15.J in the manual for instructions to remove the fixed glass assembly.

• Clean glass with a non-abrasive commercially available cleaner. For light deposits, use a soft cloth with soap and water. For heavy deposits, use commercial fireplace glass cleaner.

• Carefully set the fixed glass assembly back in place on the fireplace, secure the glass latches, and reinstall the door or decorative front.

The following tasks may be performed annually by the homeowner. More frequent cleaning may be required due to lint from carpeting or other factors.

Doors, Surrounds, Fronts:

• Assess the condition of the screen and replace as necessary.

• Inspect for scratches, dents, or other damage and repair as necessary.

• Check that louvers are not blocked.

• Vacuum and dust surfaces.

Remote Control:

• Locate the remote control transmitter and receiver.

• Verify the operation of the remote.

• Replace batteries as needed in remote transmitters and battery-powered receivers.

• Place the remote control out of reach of children.

Venting:

• Inspect venting and termination cap for blockage or obstruction such as plants, bird nests, leaves, snow, debris, etc.

• Verify termination cap clearance to subsequent construction.

• Inspect for corrosion or separation.

• Verify weather stripping, sealing, and flashing remains intact.

• Inspect the draft shield to verify it is not damaged or missing.

Lava Rock: Place lava rock on the sides and front of the hearth pan as indicated in the placement diagram.

Vermiculite: Sprinkle vermiculite over the lava rock.

Rockwool:

WARNING! Risk of Explosion! Follow rockwool placement instructions. Do not place rockwool directly over burner ports. Improperly placed rockwool interferes with proper burner operation.

• Place a small amount of 1/2 in. diameter pieces (dime-size) of rockwool on the burner pan so that the rockwool touches but does not cover the holes in the burner pan.

1. The base logs have been permanently mounted on the grate assembly and should not be moved.

2. Install the “Y” log on the left-hand side of the grate using the locating pins to position it.

3. Install the right top log using the locating pins to position it log properly.

WARNING! Risk of Asphyxiation! Handle fixed glass assembly with care. Inspect the gasket and glass for damage.

Removing Fixed Glass Assembly:

1. Lift and pull the upper grille towards you to expose the Quick Access Latches.

2. Open the control access panel to expose the lower Quick Access Latches.

3. Rotate the bottom of the screen assembly away from the appliance and lower it out of the top retainers.

4. Release top and bottom access latches and rotate the top of the glass assembly away from the top of the appliance.

5. Place the glass assembly on a surface that will not scratch it.

Replacing Fixed Glass Assembly:

1. Replace the glass assembly on the lower access latches and rotate the upper portion of the glass assembly into place.

2. Engage the top access latches.

3. Engage the lower access latches.

4. Reinstall the top corners of the screen assembly in their retainer clips and rotate the screen assembly to rest on the lower latches.

5. Close the access panel and reinstall the upper grille.

Air shutter settings should be adjusted by a qualified installer at the time of installation. The air shutter is set at the factory for a minimum vertical vent run. Adjust the air shutter for longer vertical runs.

• 16 full turns of the shutter adjustment handle are required to move the air shutter from fully open to fully closed.

• When the shutter adjustment handle is all the way down, the air shutter is in the closed position.

NOTICE: If sooting occurs, provide more air by opening the air shutter.

Caliber CD Series	CD4236
Standing Pilot or IPI
Max/Min Input Rate (NG)	30,000/20,000
Orifice Size (NG)	.104 in./2.64 mm
Max/Min Input Rate (LP)	29,500/20,000
Orifice Size (LP)	.065 in./1.65 mm

NOTICE: If the heating value of the gas has been reduced, these rules do not apply. Check with your local gas utility or authorities having jurisdiction.

When installing above 2000 feet elevation:

• In the USA: Reduce input rate 4% for each 1000 feet above 2000 feet.

• In CANADA: Reduce input rate 10% for elevations between 2000 feet and 4500 feet. Above 4500 feet, consult local gas utility.

Check with your local gas utility to determine the proper orifice size.

Symptom	Possible Causes	Corrective Action
1. After repeated triggering of the piezo ignitor button, the spark ignitor will not light the pilot.	A. No gas or low gas pressure.	Check the remote shut-off valves from the appliance. Usually, there is a valve near the gas main.
	B. No LP in tank.	Check the LP (propane) tank. You may be out of fuel.
	C. Ignitor.	Check the spark at the electrode and pilot. If no spark and electrode wire is properly connected, replace the ignitor. Verify that there is no short in electrode wire.
	D. Pilot or misaligned electrode (spark at electrode).	Using a match, light the pilot. If the pilot lights, turn off the pilot and trigger the piezo ignitor button again. If the pilot lights, an improper gas/air mixture caused the bad lighting and a longer purge period is recommended. If the pilot will not light, ensure the gap at the electrode and pilot is one-eighth inch to have a strong spark. If the gap is OK, replace the pilot.
2. The pilot will not stay lit after carefully following the lighting instructions.	A. Thermocouple.	Check that the pilot flame impinges on the thermocouple. Ensure the thermocouple connection at the gas valve is fully inserted and tight. Verify proper voltage output from the thermocouple (should be 8-16 millivolts). If less than 8 millivolts, replace thermocouple.
	B. Improper gas inlet pressure.	Natural gas should be 5-7 in. w.c. LP should be 11-14 in. w.c. Verify pressure with manometer.
	C. Valve.	If the thermocouple is producing 8-16 millivolts, replace control valve.
3. The pilot is burning, there is no burner flame.	A. On/off switch or wires defective.	Check the ON/OFF switch and wires for proper connections. Place jumper wires across the terminals at the ON/OFF switch. If the burner comes on, replace the switch. If not, check wires at the gas valve.
	B. Thermopile may not be generating sufficient millivoltage.	Check that the pilot flame impinges thermopile properly. Be sure wire connections are tight. Check the thermopile with a millivolt meter (should read 350 millivolts minimum). Replace if below minimum.
	C. Failed valve.	Turn the valve knob to the ON position. Place the ON/OFF switch in the ON position. Check the millivolt meter at the thermopile terminals. The reading should be greater than 125mV. If acceptable, and the burner does not come on, replace the gas valve.
	D. Plugged burner orifice.	Check the burner orifice for stoppage. Remove stoppage.
	E. Wall switch or wires.	Check the wall switch and wires for proper connections. Place jumper wires across terminals at the wall switch. If burner comes on, replace switch. If not, check wires at the gas valve.
4. Frequent pilot outage problem.	A. Pilot flame may be too high or too low, or blowing out.	Clean thermocouple and adjust the pilot flame for proper flame impingement. Follow lighting instructions carefully.
5. The pilot and main burner extinguish while in operation.	A. No LP in tank.	Check the LP (propane) tank. Refill the fuel tank.
	B. Improper gas inlet pressure.	Verify with manometer. NG should read 5-14 inches w.c. LP should read 10-14 inches w.c.
	C. Inner vent pipe leaking exhaust gases back into the system.	Check venting system for damage. Replace/repair improperly assembled pipe sections.
	D. Glass installed improperly.	Check to ensure glass is installed properly. Replace glass panel assembly.
	E. Failed thermopile or thermocouple.	Replace pilot if necessary.
	F. Improper vent cap installation.	Check for proper installation and freedom from debris or blockage.
6. Glass soots.	A. Flame impingement.	Adjust the log set so that the flame does not excessively impinge on it.
	B. Improper air shutter setting.	Refer to manual for shutter set points. If unit has an adjustable shutter, it may be necessary to increase shutter opening.
	C. Debris around air shutter.	Inspect the opening at the base of the burner. NO MATERIAL SHOULD BE PLACED IN THIS OPENING.
7. Flame burns blue and lifts off burner.	A. Insufficient oxygen being supplied.	Ensure that the vent cap is installed properly and free of debris. Ensure vent system joints are tight. Ensure no debris is in the air holes beneath the burner. Ensure glass is tightened properly.

Symptom	Possible Cause	Corrective Action
1. Pilot won’t light. The ignitor/module makes noise, but no spark.	A. Incorrect wiring.	Verify “S” wire (white) for sensor and “I” wire (orange) for ignitor are connected to correct terminals on module and pilot assembly.
	B. Loose connections or electrical shorts in the wiring.	Verify no loose connections or electrical shorts in wiring from module to pilot assembly. Verify connections are not grounding out to metal chassis.
	C. Ignitor gap is too large.	Verify gap of igniter to right side of pilot hood. The gap should be approximately .17 inch or 1/8 in. (3 mm).
	D. Module.	Turn ON/OFF switch to OFF. Remove ignitor wire “I” from module. Place a grounded wire about 3/16 in. away from “I” terminal on module. Turn switch ON. If no spark at “I” terminal, module must be replaced. If there is a spark, inspect pilot assembly for shorted sparker wire or cracked insulator.
2. Pilot won’t light, there is no noise or spark.	A. No power or power supply installed incorrectly.	Verify that power supply is installed and plugged into module. Check voltage of power supply under load (should be between 3.2 and 2.8 volts AC).
	B. A shorted or loose connection in wiring.	Remove and reinstall the wiring harness that plugs into module. Verify a tight fit. Verify continuity of each wire in wiring harness.
	C. Improper wall switch wiring.	Verify that 110/VAC power is “ON” to junction box.
	D. Module not grounded.	Verify black ground wire from module wire harness is grounded to metal chassis of appliance.
	E. Module.	Turn switch to OFF. Remove ignitor wire “I” from module. Turn switch ON. If no spark at “I” terminal, module must be replaced. If there is a spark, inspect pilot assembly for shorted sparker wire.
3. Pilot sparks, but Pilot will not light.	A. Gas supply.	Verify that incoming gas line ball valve is “open”. Verify that inlet pressure reading is within acceptable limits.
	B. Ignitor gap is incorrect.	Verify that spark gap from ignitor to pilot hood is .17 in. or 1/8 in (3 mm).
	C. Module is not grounded.	Verify module is securely grounded to metal chassis of appliance.
	D. Module voltage output / Valve/ Pilot solenoid ohms readings.	Verify battery voltage is at least 2.7 volts. Replace batteries if voltage is below 2.7.
4. Pilot lights but continues to spark, and main burner will not ignite.	A. A shorted or loose connection in flame sensing rod.	Verify all connections to wiring diagram. Verify connections are not grounding out to metal chassis, pilot burner, etc.
	B. Poor flame rectification or contaminated flame sensing rod.	With fixed glass assembly in place, verify that flame is engulfing flame sensing rod on left side of pilot hood. Flame sensing rod should glow shortly after ignition.
	C. Module is not grounded.	Verify module is securely grounded to metal chassis of appliance. Verify that wire harness is firmly connected to the module.
	D. Damaged pilot assembly or contaminated flame sensing rod.	Verify that ceramic insulator around the flame sensing rod is not cracked, damaged, or loose. Clean flame sensing rod with emery cloth to remove contaminants. Verify continuity with a multimeter.
	E. Module.	Turn switch to OFF. Remove ignitor wire “I” from module. Turn switch ON. If no spark at “I” terminal, module must be replaced. If there is a spark, module is fine.