HEATILATOR CD4842IR (01) PDF Document

If you smell gas while operating your HEATILATOR CD4842IR, follow these instructions:

• 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.

The glass and other surfaces of the HEATILATOR CD4842IR are hot during operation and cool down. Hot glass will cause burns.

• Do not touch the glass until it is cooled.

• NEVER allow children to touch the 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 been supplied with an integral barrier to prevent direct contact with the fixed glass panel. Do NOT operate the appliance with the barrier removed.

HEATILATOR CD4842IR
Standing Pilot or IPI
Max/Min Input Rate (NG)	33,000/22,000
Orifice Size (NG)	.109 in./2.77 mm
Max/Min Input Rate (LP)	32,500/20,500
Orifice Size (LP)	.067 in./1.70 mm

Yes, for installing the HEATILATOR CD4842IR 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 the local gas utility.

Check with your local gas utility to determine the proper orifice size. These rules do not apply if the heating value of the gas has already been reduced.

If you expect that small children or vulnerable adults may come into contact with the HEATILATOR CD4842IR, 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 of your HEATILATOR CD4842IR when not using it for an extended period (summer months, vacations, etc.), follow these steps:

• Remove batteries from remote controls.

• Turn off wall controls.

• Unplug the 3-volt adapter plug and remove batteries on IPI models.

• Turn off the gas control valve on standing pilot models.

Before operating your HEATILATOR CD4842IR 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.

To determine the ignition system on your HEATILATOR CD4842IR, open the control access panel and look at the gas valve assembly.

• A standing pilot ignition will have a red or black ignitor button.

• An Intellifire ignition system will not have a button.

First, read all safety information on the appliance label. The IPI system automatically lights the pilot; do not try to light it by hand.

1. STOP! Read the safety information on the label.

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

3. Turn off all electric power to the appliance.

4. Wait five minutes to clear out any gas. If you then smell gas, STOP! Follow the instructions for what to do if you smell gas. If you don’t smell gas, proceed to the next step.

5. 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.

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. Follow these instructions exactly:

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

2. Remove the control access panel.

3. Turn the manual gas valve to CLOSED. Wait five minutes to clear out any gas. If you then smell gas, STOP! Follow the “WHAT TO DO IF YOU SMELL GAS” instructions. If you don’t smell gas, continue.

4. Turn the gas line to “OPEN”.

5. Turn the 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 the 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 the knob and turn it counterclockwise to “ON”.

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

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 HEATILATOR CD4842IR.

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

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

3. Remove the fixed glass assembly.

4. Clean the fixed glass assembly.

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

Open windows for air circulation during the fireplace break-in, as some people may be sensitive to smoke and odors, and smoke detectors may activate.

The HEATILATOR CD4842IR may be equipped with a high/low flame adjustment control.

1. Open the control access panel.

2. Compare your valve to the figures in the manual to identify it.

3. Adjust the flame by turning the knob as indicated in the photo matching your valve.

This is a result of gas combustion and temperature variations. As the HEATILATOR CD4842IR warms, this condensation will disappear.

This is a result of normal operation on the HEATILATOR CD4842IR. The flames will begin to yellow as the appliance is allowed to burn for 20 to 40 minutes.

When first operated, the HEATILATOR CD4842IR 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.

This is a normal result of the curing process of the paint and logs on your HEATILATOR CD4842IR. The glass should be cleaned within 3 to 4 hours of initial burning. A non-abrasive cleaner such as a gas appliance glass cleaner may be necessary.

The noise is caused by metal expanding and contracting as the HEATILATOR CD4842IR 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.

In an IntelliFire ignition system (IPI), the pilot flame should turn off when the HEATILATOR CD4842IR is turned off. Some optional control systems available with IPI models may allow the pilot flame to remain lit. In a standing pilot system, the pilot will always stay on.

Glass cleaning should be performed seasonally. The fireplace should be turned off and cooled before servicing.

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

2. Remove the door or decorative front from the fireplace.

3. Remove the fixed glass assembly per instructions in Section 15.J.

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

5. Carefully set the fixed glass assembly back in place on the fireplace. Hold the glass in place with one hand and secure the glass latches with the other hand.

6. Reinstall the door or decorative front.

This can be performed by the homeowner seasonally:

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

• Verify termination cap clearance to subsequent construction (building additions, decks, fences, or sheds).

• Inspect for corrosion or separation.

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

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

Gas Pressure	Natural Gas	Propane
Minimum inlet pressure	5.0 in. w.c.	11.0 in. w.c.
Maximum inlet pressure	10.0 in. w.c.	13.0 in. w.c.
Manifold pressure	3.5 in. w.c.	10.0 in. w.c.

• Base logs have been permanently mounted on the grate assembly and should not be moved.

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

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

• **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:** Place a small amount of 1/2 in. diameter pieces (dime-size) of rockwool on the burner pan so that it touches but does not cover the holes in the burner pan. Do not place rockwool directly over burner ports.

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 the 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.

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

Possible Causes	Corrective Action
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. There can be more than one valve between the appliance and the 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 the 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.

Possible Causes	Corrective Action
A. Thermocouple.	Check that the pilot flame impinges on the thermocouple. Adjust the pilot for proper flame impingement. Ensure that the thermocouple connection at the gas valve is fully inserted and tight (hand tighten plus 1/4 turn). A qualified technician should verify proper voltage output (8-16 millivolts). If low, replace the 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 a manometer.
C. Valve.	If the thermocouple is producing 8-16 millivolts, a qualified technician should replace the control valve.

Possible Causes	Corrective Action
A. On/off switch or wires defective.	Check the ON/OFF switch and wires for proper connections. A qualified technician can place jumper wires across the terminals at the ON/OFF switch. If the burner comes on, replace the ON/OFF switch. If the switch is OK, place the jumper wires across the ON/OFF switch wires at the gas valve. If the burner comes on, the wires are faulty or connections are bad.
B. Thermopile may not be generating sufficient millivoltage.	Check that the pilot flame impinges the thermopile properly. Be sure the wire connections from the thermopile at the gas valve terminals are tight and that the thermopile is fully inserted into the pilot bracket. A qualified technician can check the thermopile with a millivolt meter. The reading should be 350 millivolts minimum. Replace the thermopile if the reading is below the specified minimum.
C. Failed valve.	Turn the valve knob to the ON position. Place the ON/OFF switch in the ON position. A technician should check the millivolt meter at the thermopile terminals. The reading should be greater than 125mV. If the reading is acceptable and the burner does not come on, replace the gas valve.
D. Plugged burner orifice.	Check the burner orifice for stoppage. Remove stoppage.

Possible Causes	Corrective Action
A. No LP in tank.	Check the LP (propane) tank. Refill the fuel tank.
B. Improper gas inlet pressure.	Verify with a 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 the venting system for damage. Replace/repair improperly assembled pipe sections.
D. Glass installed improperly.	Check to ensure the glass is installed properly. Replace the glass panel assembly if needed.
E. Failed thermopile or thermocouple.	Replace pilot if necessary.
F. Improper vent cap installation.	Check for proper installation and freedom from debris or blockage.

Possible Causes	Corrective Action
A. Flame impingement.	Adjust the log set so that the flame does not excessively impinge on it. Refer to log instructions.
B. Improper air shutter setting.	Refer to the manual for shutter set points. Ensure the set point is correct for the appliance/gas type. If the unit has an adjustable shutter, it may be necessary to increase the shutter opening.
C. Debris around air shutter.	Inspect the opening at the base of the burner. NO MATERIAL SHOULD BE PLACED IN THIS OPENING.

This indicates insufficient oxygen being supplied.

• Ensure that the vent cap is installed properly and free of debris.

• Ensure that the vent system joints are tight and have no leaks.

• Ensure that no debris has been placed at the base of, or in the area of, the air holes in the center of the base pan beneath the burner.

• Ensure that the glass is tightened properly on the unit, particularly on the top corners.

Possible Cause	Corrective Action
A. Incorrect wiring.	Verify “S” wire (white) for sensor and “I” wire (orange) for ignitor are connected to the correct terminals on the module and pilot assembly.
B. Loose connections or electrical shorts in the wiring.	Verify no loose connections or electrical shorts in wiring from the module to the pilot assembly. Verify connections underneath the pilot assembly are tight; also verify connections are not grounding out to the metal chassis, pilot burner, pilot enclosure, mesh screen if present, or any other metal object.
C. Ignitor gap is too large.	Verify the gap of the ignitor to the right side of the pilot hood. The gap should be approximately 1/8 in. (3 mm).
D. Module.	A qualified technician should test the module for spark. If there is no spark at the “I” terminal, the module must be replaced. If there is a spark, inspect the pilot assembly for a shorted sparker wire or cracked insulator around the electrode.

Possible Cause	Corrective Action
A. No power or power supply installed incorrectly.	Verify that the power supply is installed and plugged into the module. Check the voltage of the power supply under load at the spade connection on the module with the ON/OFF switch in the ON position. Acceptable readings of a good power supply are 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 the module. Verify a tight fit. Verify pilot assembly wiring to the module. A technician can check the continuity of each wire.
C. Improper wall switch wiring.	Verify that 110/VAC power is “ON” to the junction box.
D. Module not grounded.	Verify the black ground wire from the module wire harness is grounded to the metal chassis of the appliance.
E. Module.	A qualified technician should test the module. If there is no spark at the “I” terminal, the module must be replaced. If there is a spark, inspect the pilot assembly for a shorted sparker wire or cracked insulator.

Possible Cause	Corrective Action
A. Gas supply.	Verify that the incoming gas line ball valve is “open”. Verify that the inlet pressure reading is within acceptable limits.
B. Ignitor gap is incorrect.	Verify that the spark gap from the ignitor to the pilot hood is 1/8 in. (3 mm).
C. Module is not grounded.	Verify the module is securely grounded to the metal chassis of the appliance.
D. Module voltage output / Valve/ Pilot solenoid ohms readings.	Verify the battery voltage is at least 2.7 volts. Replace batteries if the voltage is below 2.7.

This indicates that flame rectification has not occurred.

Possible Cause	Corrective Action
A. A shorted or loose connection in the flame sensing rod.	Verify all connections per the wiring diagram. Verify connections underneath the pilot assembly are tight and not grounding out to the metal chassis or other objects.
B. Poor flame rectification or contaminated flame sensing rod.	With the fixed glass assembly in place, verify that the flame is engulfing the flame sensing rod on the left side of the pilot hood. The flame sensing rod should glow shortly after ignition. Verify the correct pilot orifice is installed and the gas inlet is set to pressure specifications.
C. Module is not grounded.	Verify the module is securely grounded to the metal chassis of the appliance. Verify that the wire harness is firmly connected to the module.
D. Damaged pilot assembly or contaminated flame sensing rod.	Verify that the ceramic insulator around the flame sensing rod is not cracked, damaged, or loose. Verify the connection from the flame sensing rod to the white sensor wire. Clean the flame sensing rod with emery cloth to remove any contaminants. A technician can verify continuity with a multimeter. Replace the pilot if any damage is detected.
E. Module.	A qualified technician can test the module for spark. If there is no spark at the “I” terminal, the module must be replaced. If there is a spark, the module is fine.