VENT-FREE GAS FIREPLACE INSERT OWNER’S OPERATION AND INSTALLATION MANUAL MODELS PCS100T AND PCS150T WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the v icinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance.
TABLE OF CONTENTS Safety......................................................... 3 Qualified Installing Agency......................... 4 Specifications............................................. 5 Product Features........................................ 5 Local Codes............................................... 5 Unpacking.................................................. 6 Product Identification.................................. 6 Water Vapor: A By-Product Of Unvented Room Heaters....................
SAFETY WARNING: Do not attempt to access or change the setting of the fuel selection means. Access to and adjustment of the fuel selection means must only be performed by a qualified service person when connecting this appliance to a specified fuel supply at the time of installation. Change of the selector setting to other than the fuel type specified at the time of the installation could damage this appliance and render it inoperable.
SAFETY WARNING: Do not allow fans to blow directly into fireplace. Avoid any drafts that alter burner flame patterns. WARNING: Do not use a blower insert, heat exchange insert or other accessory not approved for use with this heater. WARNING: Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies. WARNING: Clothing or other flammable material should not be placed on or near the appliance. Never place any objects in the heater.
SPECIFICATIONS Model PCS100T PCS150T Gas Type Natural Gas Propane Gas Natural Gas Propane Gas Maximum Input Rating 10,000 Btu/Hr 10,000 Btu/Hr 15,000 Btu/Hr 15,000 Btu/Hr Minimum Input Rating 5,000 Btu/Hr 8,000 Btu/Hr 7,000 Btu/Hr 11,000 Btu/Hr Pressure Regulator Setting 4" W.C. 9" W.C. 4" W.C. 9" W.C. Max. 9.5" Max. 14" Max. 9.5" Max. 14" Inlet Gas Pressure* (inches of water) Min. 5" Min. 11" Min. 5" Min. 11" Ignition Electronic Piezo Heater Dimensions (WxHxD) • 16" × 27.7" × 10.
UNPACKING 1. 2. 3. 4. 5 6. Remove top inner pack. Tilt carton so that heater is upright. Remove protective side packaging. Slide heater out of carton. Remove protective plastic wrap. Hold the screen, lift, and pull forward. 7. Remove log set by cutting plastic ties. 8. Carefully unwrap log. 9. Check for any shipping damage. If heater or log is damaged, promptly inform your dealer where you bought the heater.
QUALIFIED INSTALLING AGENCY Only a qualified agency should install and replace gas piping, gas utilization equipment or accessories, and repair and equipment servicing.
AIR FOR COMBUSTION AND VENTILATION VENTILATION AIR Ventilation Air From Inside Building This fresh air would come from an adjoining unconfined space. When ventilating to an adjoining unconfined space, you must provide two permanent openings: one within 12" of the ceiling and one within 12" of the floor on the wall connecting the two spaces (see options 1 and 2, Figure 2). You can also remove door into adjoining room (see option 3, Figure 2). Follow the National Fuel Gas Code, ANSI Z223.
INSTALLATION NOTICE: This heater is intended for use as supplemental heat. Use this heater along with your primary heating system. Do not install this heater as your primary heat source. If you have a central heating system, you may run system’s circulating blower while using heater. This will help circulate the heat throughout the house. In the event of a power outage, you can use this heater as your primary heat source. WARNING: A qualified service person must install heater. Follow all local codes.
INSTALLATION GAS SELECTION This appliance is factory preset for propane gas. No changes are required for connecting to propane. Only a qualified installer or service technician can perform gas selection and connecting to gas supply. Yellow Natural Gas Plunger Underneath Metal Cap Blue Propane Gas Plunger DO NOT REMOVE! CAUTION: Two gas line installations at the same time are prohibited.
INSTALLATION FOR NATURAL GAS INSTALLATION: YELLOW 1. Remove the metal cap installed over the NG regulator inlet. Metal Cap 2. Install metal cap over propane regulator inlet. This will keep debris out of regulator. DO NOT REMOVE Metal Cap Yellow Natural Gas Plunger Install Gas Fitting Here Use only the cap supplied on the regulator. Do not use an off the shelf pipe plug. This can damage the plunger. The supplied regulator cap is designed so it will not engage the unused gas type. Use only the metal cap.
INSTALLATION BUILT-IN FIREPLACE INSTALLATION WARNING: Do not allow any combustible materials to overlap the firebox front. WARNING: Do not allow combustible or noncombustible materials to cover any necessary openings like louvered slots. 1/4" Clearance to Facia 3/8" Clearance to Sides, Back and Top 15 5/8" 16" WARNING: Never modify or cover the louvered slots on the front of the firebox.
19" 90° 25 3. Attach gas line to fireplace gas regulator. See Connecting to Gas Supply, page 13. 4. Check all gas connections for leaks. See Checking Gas Connections, page 15. IMPORTANT: When finishing your firebox, combustible materials such as wall board, gypsum board, sheet rock, drywall, plywood, etc, must have 1/2" clearance to the sides and top of the firebox. Combustible materials should never overlap the firebox front facing.
INSTALLATION CONNECTING TO GAS SUPPLY WARNING: A qualified service technician must connect heater to gas supply. Follow all local codes. CAUTION: Avoid damage to regulator. Hold gas regulator with wrench when connecting into gas piping and/or fittings. WARNING: This appliance requires a 3/8" NPT (National Pipe Thread) inlet connection to the pressure regulator. CAUTION: Use pipe joint sealant that is resistant to gas (Propane or Natural Gas).
INSTALLATION The installer must supply an external regula- Install sediment trap in supply line as shown tor. The external regulator will reduce incom- in Figure 12. Place sediment trap where it is ing gas pressure. You must reduce incoming within reach for cleaning. Place sediment trap gas pressure to between 11" and 14" of water. where trapped matter is not likely to freeze. If you do not reduce incoming gas pressure, A sediment trap traps moisture and contamiheater regulator damage could occur.
INSTALLATION CHECKING GAS CONNECTIONS WARNING: Test all gas piping and connections for leaks after installing or servicing. Correct all leaks at once. WARNING: Never use an open flame to check for a leak. Apply a noncorrosive leak detection fluid to all joints. If bubbles form, there is a leak. Correct all leaks at once. PRESSURE TESTING GAS SUPPLY PIPING SYSTEM Test Pressures In Excess Of 1/2 PSIG (3.5 kPa) 1.
INSTALLATION PRESSURE TESTING HEATER GAS CONNECTIONS 1. Open equipment shutoff valve (see Figure 17, page 15). Apply a noncorrosive leak 15, page 16). detection fluid to all joints. Bubbles forming show a leak. 2. Open main gas valve located on or near gas meter for natural gas or open propane 5. Correct all leaks at once. supply tank valve. 6. Light heater (see Lighting Instructions on 3. Make sure control knob of heater is in the page 18). Check all other internal joints OFF position. for leaks. 4.
INSTALLATION BATTERY INSTRUCTIONS CAUTION: Do not dispose of batteries in fire, batteries may explode or leak. • Battery is included. • Remove battery when depleted. • Be sure to observe proper polarity (+/-) when installing or replacing the battery. Damage due to improper battery installation may void the warranty on the 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.
OPERATION LIGHTING INSTRUCTIONS WARNING: You must operate this heater with the screen in place. Make sure screen is installed before running heater. NOTICE: During initial operation of new heater, burning logs will give off a paper-burning smell. Orange flame will also be present. Open damper or window to vent smell. This will only last a few hours. 1. STOP! Read the safety information above. 2. Unscrew ignitor cap and install a AAA battery with the + pointing out. Replace cap. 3.
OPERATION THERMOSTAT CONTROL OPERATION The thermostatic control used on this model differs from standard thermostats. Standard thermostats simply turn the burner on and off. The thermostat used on this heater senses the room temperature. At times the room may exceed the set temperature. If so, the burner will shut off. The burner will cycle back on when room temperature drops below the set temperature. The control knob can be set to any comfort level between HIGH (5) and LOW (1).
INSPECTING BURNERS Natural Gas Shown Natural Gas Shown NG 3-3.5" WC LP 8-11" WC NG 3-3.5" WC LP 8-11" WC Approx. 3"-6" Above Top of Logs Figure 24 - Correct Pilot Flame Pattern (Natural Gas shown) Figure 25 - Incorrect Pilot Flame Pattern (Natural Gas shown) BURNER FLAME PATTERN Figure 26 shows a correct burner flame pattern. Figure 27 shows an incorrect burner flame pattern. If burner flame pattern is incorrect then: • turn heater off (see To Turn Off Gas to Appliance, page 19).
CARE AND MAINTENANCE CLEANING BURNER PILOT AIR INLET HOLE We recommend that you clean the unit every 2,500 hours of operation or every three months. We also recommend that you keep the burner tube and pilot assembly clean and free of dust and dirt. To clean these parts we recommend using compressed air no greater than 30 PSl. Your local computer store, hardware store, or home center may carry compressed air in a can. You can use a vacuum cleaner in the blow position.
TROUBLESHOOTING WARNING: If you smell gas: • Shut off gas supply. • 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. WARNING: Only a qualified service technician should service and repair heater. Make sure that power is turned off before proceeding.
TROUBLESHOOTING Problem Possible Cause Corrective Action When ignitor button is 1. Low battery. 1. Replace battery. pressed in, there is no 2. Ignitor electrode is not con- 2. Reattach ignitor cable spark at ODS/pilot nected to ignitor cable. 3. Ignitor cable is pinched or 3. Free ignitor cable if pinched wet. by any metal or tubing. Keep ignitor cable dry. 4. Ignitor electrode is posi- 4. Replace electrode. tioned wrong. Ignitor electrode is broken. 5 Broken ignitor cable. 5. Replace ignitor cable. 6.
TROUBLESHOOTING Problem Possible Cause Corrective Action Burner(s) does not light 1. Burner orifice is clogged. after ODS/pilot is lit 1. Clean burner orifice (see Care and Maintenance, page 21). 2. Inlet gas pressure is too low. 2. Contact local gas supplier. 3. Burner orifice diameter is too 3. Replace gas train. small. Delayed ignition of 1. Manifold pressure is too low. 1. Contact local gas supplier. burner(s). 2. Burner orifice is clogged. 2. Clean burner (see Care and Maintenance, page 21).
TROUBLESHOOTING Problem Possible Cause Corrective Action Heater produces a whis- 1. Turning control knob to high 1. Turn control knob to low (1) tling noise when burner (5) position when burner is position and let warm up for is lit. cold. a minute. 2. Air in gas line. 2. Operate burner until air is removed from line. Have gas line checked by local gas supplier. 3. Air passageways on heater 3 Observe minimum installaare blocked. tion clearances (Figure 4, page 9) 4.
REPLACEMENT PARTS Note: Use only original replacement parts. This will protect your warranty coverage for parts replaced under warranty. PARTS UNDER WARRANTY Contact authorized dealers of this product. If they can’t supply original replacement parts, call Customer Service toll free at 1-866-573-0674 for referral information.
PARTS MODEL PCS100T & PCS150T 2 1 3 4 28 www.usaprocom.
PARTS MODEL PCS100T & PCS150T This list contains replaceable parts for your heater. When ordering replacement parts, follow the instructions listed under Replacement Parts on page 27 of this manual. ITEM PART # DESCRIPTION QTY 1 150PCS102B-02 Screen Assembly 1 2 15T1500B-01 Gas Train Assembly 1 3 PIMDN1-01 Ignitor 1 4 15T1004B-01 Log Set 1 PART AVAILABLE - NOT SHOWN 200159-01B ML065-01 Thermostat Bulb Clip 2 150T2009-01 Hardware Package 1 www.usaprocom.
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WARRANTY KEEP THIS WARRANTY Model ________________________________ Serial No. _____________________________ Date Purchased ________________________ Keep receipt for warranty verification. REGISTER YOUR PRODUCT AT WWW.USAPROCOM.COM IMPORTANT: We urge you to register your product within 10 days of date of installation, complete with entire serial number which can be found on the rating plate. Please fill out the warranty information above for your personal records. Retain this manual for future reference.