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. Portland US Report No. 050-S-14b-2 Ce manuel d’installation est disponible en francais, simplement en faire la demande. Numéro de la pièce 775,229CF. These appliances must be properly installed and operated in order to prevent the possibility of a house fire.
IMPORTANT SAFETY AND WARNIING INFORMATION read THIS MANUAL IN ITS ENTIRETY and understand these Rules to follow for safety. WARNING Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier. WARNING Do not attempt to alter or modify the construction of the appliance or its components.
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 available 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.
Planning Your Installation Questions To Ask Local Building Official A correct installation is critical and imperative for reducing fire hazards and perilous conditions that can arise when wood pellet burning appliances are improperly installed. The installer must follow all of the manufacturers’ instructions. WARNING Check all local building and safety codes before installation. The installation instructions and appropriate code requirements must be followed exactly and without compromise.
Installation Options • 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. Heating 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).
2-1/2” Minimum Screen Pocket is Needed for the Control Board (not applicable if P/N 79032 ZC Surround Kit is used*) INSERT Dimensions Front View 23” (584mm) Minimum 15-1/2” 15” (394mm) (381mm) 26-1/4” (667mm) 36” (914mm) Minimum* Control Board Side Surround Panel 23-3/8” (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.
Hearth Protection Clearances to Combustibles IMPORTANT • Minimum clearances specified may not allow for ease of operation and maintenance (please take this in to account when planning the installation). • Recommended clearance zone from the front of the appliance to combustibles is 4 feet minimum. • Clearances to combustibles for the appliance can only be reduced by means approved by the regulatory authority.
Installation Vent Termination Requirements: If the insert is not vented vertically, the following apply: Control Board Installation 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.
Vent Termination Locations Air Supply Inlet Vent Terminal Area Where Terminal Is Not Permitted Vertical Terminal 24” (610mm) Vertical Terminal G (From Eave) 24” (610mm) A D E M Fixed Closed B H B C N L B K F J A B A= B= B Able To Open Clearance above grade, veranda, porch, deck, or balcony (min. L= 12”/30cm) M = **Clearance above paved sidewalk or a paved driveway located on public property *(min. 84”/2.1m) Clearance to window or door that may be opened (min. 12”/30cm above - 48”/1.
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).
Mobile Home Installations Fireplace Installation Using Standard Surround Kits (P/N 79004, 79005, 79006 and 79007) The following steps are required for installation of the Winslow™ PI40 insert in mobile homes. See Figure 12. FIREPLACE OPENING C/L 36" FIREPLACE OPENING 18" 13-1/2" 2-15/16" CONTROL BOARD 11" 41" SURROUND WIDTH WARNING: DO NOT INSTALL THIS INSERT IN A SLEEPING ROOM IN A MANUFACTURED HOME. 19-1/4" 138° 7-7/16" HEARTH / FLOOR PROTECTION 6-11/16" 1.
Outside Air Installations Door Trim Installation Instructions Connecting the Winslow PI40 insert to outside combustion air is optional, except in mobile home installations and when required by local building codes. The fireplace 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.
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 Figure 15 6. Finish tightening nuts.
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.
Brick Panel Installation 2. Remove all pellets and ash from the firebox to ensure a proper fit for the brick panel. 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 Figure 25 B Note: The brick panel comes pre-painted with Metallic Black paint.
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 16 NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
Log Set Installation Instructions Kit Contents (refer to Figure 30) Cat. No. #H5142 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.
Operation Control Board The control board regulates all functions of the insert. The following is a list of the board’s components: • 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.
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. 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. Corn Fuel Power Outage - If the insert loses electrical power for less than 10 seconds it will continue to operate.
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 following 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.
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 motor, a new gasket may need to be installed between the motor and the fan housing.
Cleaning the Convection Blower To clean the convection blower, remove the left side door (see the following page). Disconnect the insert power cord from the electrical outlet. 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.
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.
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.
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 causing 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.
Diagnostic Codes If the insert operates abnormally, the ready light on the control board will signal the nature of the abnormal operation.
Over Temperature Snap Switch Shuts Insert Down - Code - Ready light flashes red 2 long blinks Possible Problem Solution Convection blower not running Blower dirty, blower snap switch bad, or blower broken Flue passageways or vent restricted Clean passageways or vent pipe (see Pages 20 and 21) Snap switch* defective Replace the snap switch* * Note: The snap switch has a reset button that must be pushed before insert will function (see Page 24).
Accessories Zero Clearance Kit Surround Panel Kits (required - sold separately) Cat. No. Model 79004 PI40-FPK2941 Cat. No. Model Description 79025 PI40-ZCK PI40-HK PI40-HK30411 30-5/8” Ht. x 41” Wd. Surround Panels Zero Clearance Kit Description Pellet Heat Kits 29” Ht. x 41” Wd. Black Trim Pellet Heat Kit 79005 PI40-FPK2948 29” Ht. x 48” Wd. Black Trim 79024 79006 PI40-FPK3341 33” Ht. x 41” Wd. Black Trim 79026 79007 PI40-FPK3348 33” Ht. x 48” Wd.
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 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).
Pellet Insert ZC Kit Assembly Kit Contents (refer to Figure 52) B A 1 ea. Back panel (A) 1 ea. Left side panel (B) 1 ea. Right side panel (C) 1 ea. Top panel (D) 1 ea. Access panel (E) 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.
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. 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.
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.
ZC Framing Dimensions for Combustible /Floor Top View Exhaust 8-1/4” 8-1/4” 8-1/4” (210mm) 9-1/8” 39” 9-1/8” 9-1/8” (232mm) Front 39” 39” (991mm) Front View 8-1/4” 6-3/4” Exhaust A/C Power Cord Intake 6-3/4” 6-3/4” (172mm) 4”(102mm) 4” 3-1/2”(89mm) 3-1/2” 4” 10-3/8” 10-3/8” (264mm) 19-1/2” 19-1/2” (495mm) 25-1/2” 25-1/2” 10-3/8” (648mm) 3-1/2” 6-3/4” 16- 19-1/2” 25-1/2” Side View Outside Air Intake 29-1/2” 29-1/2” (749mm) 8-1/4” 39” Figure 63 9-1/8” A/C Power Exhaust 16-1/8” 16-
ZC Framing Dimensions for Non-Combustible Hearth /Floor Top View Exhaust 8-1/4” 9-1/8” 39” 8-1/4” 8-1/4” (210mm) 9-1/8” 9-1/8” (232mm) Front 39” 39” (991mm) Front View 8-1/4” Exhaust A/C Power Cord Intake 4-3/4” 4-3/4” (121mm) 3”(76mm) 3” 2-1/2”(64mm) 2-1/2” 10-3/8” 3” 2-1/2” 10-3/8” (264mm) 19-1/2” 19-1/2” (495mm) 25-1/2” 25-1/2” (648mm) 10-3/8” 19-1/2” 25-1/2” Outside Air Intake Side View 28” 28” (711mm) 8-1/4” 4-3/4” 34 39” Figure 64 9-1/8” A/C Power 16-1/8” 16-1/8” (410mm) NOTE:
NOTES 35
Warranty Your pellet insert is covered by a limited warranty (provided with appliance). Please read the warranty to be familiar with its coverage. Retain this manual. File it with your other documents for future reference. 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.
