NorthAmerica’sBest DV-40 STEP TOP DIRECT VENT FREESTANDING GAS STOVE (DV-40 STEP) INSTALLATION, OPERATION, VENTING AND MAINTENANCE INSTRUCTIONS Revised (8/98) CONGRATULATIONS! You are now the proud owner of one of the finest gas stoves on the market - the QUADRA-FIRE. WARNING If the information in this manual is not followed exactly a fire or explosion may result, causing property damage, personal injury or death.
TABLE OF CONTENTS PAGE Safety Label ............................................................................................................................................. 3 Safety Notices .......................................................................................................................................... 4 Specifications and Listings ....................................................................................................................... 5 Dimensions ...............
DV-40 STEP SAFETY LABEL (FOUND ON PULL-OUT ON BACK OF STOVE) Page 3
SAFETY NOTICES This stove should be installed only by a qualified installer. It is approved for installation in a bedroom. Bedroom installation in Canada requires that stove be hooked to a thermostat. The stove must be electrically grounded in accordance with local codes, or the latest edition of the National Electric Code. If no local codes exist, this stove should be installed following the current codes: CAN/CGA-B149.1............................................................
SAFETY NOTICES, CONT. WARNING Do not operate appliance with the glass front removed, cracked or broken. Replacement of the glass should be done by a licensed or qualified service person. WARNING Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual for correct installation and operational procedures. For assistance or additional information consult a qualified installer, service agency, or the gas supplier.
DIMENSIONS LEG MODEL 23 3/16" [589m m ] 21 1/2" [546m m ] 24 5/8" [625m m ] 12 9/16" [319m m ] 12 5/16" [313m m ] 6 1/8" [156m m ] 24 7/8" [632m m ] 20 5/8" [524m m ] PEDESTAL MODEL 23 3/16" [589m m ] 21 1/2" [546m m ] 24 5/8" [625m m ] 12 9/16" [319m m ] 12 5/16" [313m m ] 6 1/8" [156m m ] 21" [533m m ] 20 9/16" [522m m ] Page 6
UNPACKING THE STOVE 1. 2. Unbolt pallet using a 7/16” wrench to remove the four bolts from the underside of the pallet. Between the firebox bottom and pallet is an accessories box containing logs, nuggets, touch-up paint, an allen key, and instructions for installation of legs or pedestal. DV-40 STEP LEG ADAPTER ASSEMBLY INSTRUCTIONS 1. 2. 3. 4 5. Remove door from unit and log box located between stove and pallet. Install leg adapter front cover on front of stove as shown (Fig.
DV40 STEP PEDESTAL INSTALLATION INSTRUCTIONS 1. 2. 3. 4. Remove log box located between stove and pallet Remove door from unit. Remove pallet mounting bolts from underneath pallet and remove stove from pallet WITH FRONT DOOR REMOVED lay unit down on it’s front for easy access to bottom.(Fig. 1) NOTE: The right and left logs are fastened to the stove. Take special care while laying the stove down to not jar and fracture the logs. 5. 6. 7. 8. 9. 10. Slide pedestal assembly on to unit.
THERMOSTAT INSTALLATION If desired, a thermostat may be installed to regulate the Quadra-Fire DV-40 Step. It is important to use a thermostat designed for millivolt operation. Do not connect this stove to a thermostat serving any other appliance. Bedroom installation in Canada requires this stove to be hooked to a thermostat. OPTIONAL THERMOSTATS Manual Thermostat Part #812-2880 Anticipator Setting 1.
PLANNING YOUR INSTALLATION There are four types of direct vent system installations approved for use with the DV40 Step. It is very important to maintain a balance between the combustion air intake and the flue gas exhaust venting system. The types of installation are: Horizontal Termination (Figure 1, Pg. 11) Vertical Termination (Figure 2, Pg. 11) Into a Class A Metal Chimney (Figure 3, Pg. 11)* Into a Masonry Chimney (Figure 4, Pg.
FOR HORIZONTAL TERMINATIONS USE ONLY DURAVENT PART # 985 OR ALADDIN HEARTH PRODUCTS PART #HHW2 (See * in Figure 1 below). FOR VERTICAL TERMINATIONS USE DURAVENT PART #991. * WALL THIMBLE HORIZONTAL TERMINATION 90 ELBOW VERTICAL TERMINATION Part #991 PART #985 STORM COLLAR OR * PIPE LENGTH FLASHING FIRESTOP HORIZONTAL TERMINATION SUPPORT BOX PART #HHW2 FIG. 2 PIPE LENGTH FIG.
SIMPSON DURA-VENT PARTS LIST Simpson Dura-Vent offers a complete line of component parts for installation in both horizontal and vertical applications. Many items are offered in decorative black, as well as a galvanized finish. The galvanized pipe and fittings are used for concealed locations such as attics, or spaces where corrosion is a factor, such as above the roofline. Decorative brass and chrome trim kits are available for both wall thimbles and ceiling support boxes.
SIMPSON DURA-VENT PARTS LIST (CONT.) BASIC KITS The standard termination kit (Kit 0970A) includes the following: 990B 940 985 1 each 90° Black Elbow 1 each Round Ceiling Support/Wall Thimble 1 each High Wind Horizontal Termination Cap NOTE: The above kit is not a complete termination system. You will need to order the straight pipe lengths needed to complete the installation. The black 45° elbow is not included in this kit.
CLEARANCES TO COMBUSTIBLES Minimum clearances to combustible materials from stove body: A B C D E Left & Right of Stove (One Wall) 9” (225mm) Back wall (to Pipe) 8” (200mm) Top of unit (from Stove Top) 24” (600mm) Corner clearance* 1” (25mm) Alcove (Each Side) 12” (300mm) (Max. Depth) 36” (915mm) * In corner installations one inch is the clearance to combustibles. However, on the valve side of stove, 6 inches may be required to allow safe access to controls.
HOW TO USE VENT GRAPH 1. 2. 3. Measure the distance from the top of stove to the center of the 90° elbow. On the graph below, draw a horizontal line from that measurement on the vertical axis across until it intersects with the slanted line. From the point of this intersection, draw a vertical line to the bottom of the graph. The point at which this line meets the bottom line of the graph is the maximum length of the horizontal run.
VENTING INSTRUCTIONS PLEASE NOTE: In order to comply with applicable codes and product warranties, only Simpson DuraVent venting components may be used. DO NOT USE FIELD-FABRICATED VENTING COMPONENTS. The Quadra-Fire DV40 Step is approved to be vented either through the side wall or vertically through the roof. You may vent through a Class A or masonry chimney if a Simpson Dura-Vent adapter is used (for USA installations only).
VENTING NOTE: THIS STOVE IS A DIRECT VENT HEATER. ALL COMBUSTION AIR MUST COME DIRECTLY FROM THE OUTSIDE OF THE BUILDING. THE VENT PIPE FOR THIS UNIT CONSISTS OF AN INNER AND AN OUTER PIPE. THE INNER PIPE CARRIES THE STOVE EXHAUST OUT OF THE SYSTEM, AND THE OUTER PIPE BRINGS FRESH COMBUSTION AIR INTO THE STOVE.
HORIZONTAL INSTALLATION NOTE: RESTRICTOR STRAP IS REQUIRED IF HORIZONTAL VENTING CONFIGURATION HAS 10’ OR GREATER OF VERTICAL RISE AND NOT MORE THAN ONE 90 DEGREE ELBOW. Step 1. Set the gas stove in its desired location. Check to determine if wall studs or roof rafters are in the way when the venting system is attached. If this is the case, you may want to adjust the location of the stove. Step 2. Simpson Dura-Vent pipe is designed with special twist-lock connections.
HORIZONTAL INSTALLATION (CONT.) Step 3. With the adapter and pipe attached to the stove, slide the stove into its correct location, maintaining minimum clearance to combustibles, and mark the wall for a 10” x 10” (254mm x 254mm) square hole. The center of the square hole should line up with the centerline of the horizontal pipe, as shown in Figure 6. Cut and frame the hole in the exterior wall where the vent will be terminated. If the wall being penetrated is constructed of noncombustible material, i.e.
HORIZONTAL INSTALLATION (CONT.) Step 4. Position the horizontal vent termination in the center of the 10” (254mm) square hole, and attach to the exterior wall with the four wood screws provided. Before attaching the Vent Termination to the exterior wall, run a bead of non-hardening mastic around its outside edges, so as to make a seal between it and the wall. The arrow on the vent cap should be pointing up. Insure that proper clearances to combustible materials are maintained (Figure 7).
HORIZONTAL INSTALLATION (CONT.) Step 5. Before connecting the horizontal run of vent pipe to the vent termination, slide the black decorative wall thimble cover over the vent pipe. Step 6. Slide the stove and vent assembly towards the wall, carefully inserting the vent pipe into the vent cap assembly. It is important that the vent pipe extend into the vent cap sufficient distance so as to result in a minimum pipe overlap of 1¼” (32mm).
VERTICAL TERMINATIONS USING GS SERIES PIPE Step 1. Check the installation instructions for required 2 inch clearances (air space) to combustibles when passing through ceilings, walls, roofs, enclosures, attic rafters, or other nearby combustible surfaces. (See page 24, FIG. 16) Do not pack air space with insulation. Check the instructions below for maximum vertical rise of the venting system, and any maximum horizontal offset limitations (Figure 11).
VERTICAL TERMINATIONS (CONT.) USING GS SERIES PIPE (CONT.) Step 4. Assemble the desired lengths of GS pipe and elbows necessary to reach from the stove up through the round support box. Insure that all pipe and elbow connections are in their fully twistlocked position. Be sure to seal the outer pipe with appropriate sealant (high temperature silicone). Step 5. Cut a hole in the roof centered on the small drill hole placed in the roof in step 2.
VERTICAL TERMINATIONS (CONT.) USING GS SERIES PIPE (CONT.) Step 7. Continue to assemble pipe sections until the height of the vent cap (H) (Figure 15) meets the minimum code requirements described in code requirements as outlined in the current CAN/ CGA-Bl49 Installation Codes (in Canada), the National Fuel Gas Code NFPA 54/ANSI Z223.1 (in USA), or local codes. Note that for steep roof pitches, the vent height must be increased.
VERTICAL TERMINATIONS (CONT.) CATHEDRAL CEILING INSTALLATION Step 1. Follow installation Steps 1 and 2 under vertical termination section. Step 2. Using the plumb-bob, mark the centerline of the venting system on the ceiling, and drill a small hole through the ceiling and roof at this point. From the roof, locate the drill hole and mark the outline of the cathedral ceiling support box. Step 3. Remove shingles or other roof covering as necessary to cut the rectangular hole for the support box.
VERTICAL TERMINATIONS (CONT.) INSTALLATION INTO A CLASS A METAL CHIMNEY NOTE: Have the existing installation inspected by a qualified chimney sweep or professional installer prior to converting to direct vent. The existing chimney system must be in serviceable condition and functionally sound and clean. Step 1. Remove existing chimney cap. Step 2.
VERTICAL TERMINATIONS (CONT.) INSTALLATION INTO AN EXISTING MASONRY CHIMNEY Step 1. Before cutting any holes, assemble the desired sections of direct vent pipe to determine the center of the masonry penetration. Step 2. Once the center point of the penetration has been determined, cut a 6” (152mm) diameter hole in the masonry. If the hole is too large, the retro connector might not mount properly; if the hole is too small, the appliance might starve for intake air.
VERTICAL TERMINATIONS (CONT.) INSTALLATION INTO AN EXISTING MASONRY CHIMNEY (CONT.) Step 5. Connect the flex liner to the top adapter using three sheet metal screws (see Figure 20). Step 6. Feed the flex liner through the flashing into the chimney. Carefully feed the flex liner down the chimney to the bottom and out the opening in the masonry wall, forming an angle to line up the flex liner with the vent opening on the appliance.
VERTICAL TERMINATIONS (CONT.) INSTALLATION INTO AN EXISTING MASONRY CHIMNEY (CONT.) Step 9. Attach the flex to the retro connector. Use three sheet metal screws to attach the flex liner to the connector (Figure 26). Mount the retro connector to the masonry wall using masonry bolts. Redrill larger holes on connector as needed. Be careful to insure that the connector is centered in the opening and the mounting holes line up with the masonry wall. Step 10.
GAS LINE CONNECTION Gas line connection can be made near the lower rear of the stove (3/8” gas hookup). You must supply a shutoff valve installed in a visible location within 3’ (914 mm) of the stove. Before hooking up the stove to the gas supply, be sure that the stove you are installing is designed for the type of gas being supplied to it. There is a serial number and listing label on the rear of the stove that will indicate which type of gas it is designed to utilize.
HIGH ALTITUDE OPERATION In Canada, this unit is approved from 0 to 4500 feet above sea level. Installation of this stove at altitudes above 4500 feet is subject to field test of the individual installation and approval by the local authority having jurisdiction. In the United States, input ratings of this unit are based on sea level operation, and shall not be changed for operation at elevations up to 2000 feet.
GAS CONVERSION INSTRUCTIONS FOR LP AND NG WARNING ! The installation of this conversion kit must only be undertaken by a qualified and certified gas appliance installer. CAUTION: DISCONNECT ANY ELECTRICAL CORDS AND TURN OFF GAS SUPPLY TO UNIT BEFORE PROCEEDING. Valve Regulator Tower 1. 2. 3. 4. Turn control knob to the OFF position and shut off the gas supply to the valve.
CONVERSION INSTRUCTIONS, (CONT.) Burner Orifice Replacement 5. 6. 7. 8. 9. 10. 11. 12. Remove the right top log bracket using a Phillips screwdriver (Screws are accessed through rectangular hole in bracket.) See Fig. 4, Pg. 37 (Labeled “Peg in right log bracket”) Remove the right and left side log retaining brackets (one per side). (Top of log and firebox side.) Carefully lift logs vertically off alignment pegs and place in a safe area out of the way of traffic.
CONVERSION INSTRUCTIONS (CONT.) Pilot Tower Orifice Replacement 13. Loosen (CCW rotation) and remove pilot target hex fitting with a 7/16” end wrench as shown in figure A. FIG. A 14. Remove the currently installed orifice with a pair of needlenose pliers or other means as shown in figure B. FIG. B 15. 16. Install the conversion orifice. Reinstall the pilot target hex fitting and tighten it until the index marks align with each other as shown in figure C. FIG. C 17. 18. 19. 20. 21.
CONVERSION INSTRUCTIONS, (CONT.) Lighting and pressure testing 24. 25. 26. Apply gas to system and re-light appliance according to lighting instructions. With the main burner “ON”, test the new pressure regulator assembly for leaks using soap bubbles or a gas leak detector. Re-light the main burner in both the HI and LO positions and verify proper burner ignition and operation. INSTALLER NOTICE: These instructions must be left with appliance.
LOG INSTALLATION, CONTINUED FIGURE 1 PLACE PEG HOLES IN LOG #23 OVER PEGS IN CENTER BURNER PAN. If damage has occurred to right or left base log, and replacement is necessary, removal is illustrated in conversion instruction steps 5-7. FIGURE 2 DO NOT ALLOW NUGGETS ON BACKSIDE OF THIS PLATE. DO NOT ALLOW LONG LENGTH OF NUGGETS TO BLOCK AIR GAP BETWEEN BURNER PAN AND BURNER.
LOG INSTALLATION, CONTINUED FIGURE 4 RIGHT TOP LOG #24. PEG HOLE PEG IN RIGHT LOG BRACKET NOTCH FOR RIGHT TOP LOG FINISHED LOG SET CAUTION ! Light appliance with door open to insure there is no hesitation or delay of flame transfer through nugget bed. If ignition is noisy or delayed momentarily, the nuggets in that area may need to be rearranged. Close door and continue with flame adjustment. See “Shutter Adjustment” on following page.
FIRST FIRE NOTE: Never operate this stove with the door open. Before first firing the stove, read the owner’s manual to familiarize yourself with the stove’s features, controls, and cautions for operation. Remove all labels from glass before operating this stove for the first time. Plug power cord into a properly installed outlet for blower operation. During your first fire in the stove, you may notice an odor and steam coming from the stove.
LIGHTING INSTRUCTIONS (LOCATED ON PULL-UP AT LEFT REAR OF STOVE) Page 39
PRESSURE TESTING This appliance must be disconnected from the gas supply piping system if any testing is done to the system that exceeds the test pressure of 1/2 PSIG. If the test pressure is less than or equal to 1/2 PSIG, then this appliance must be isolated from the piping system by closing its individual shutoff valve. The gas valve is supplied with pressure test ports for checking input and output pressures. These are located just above the on/off knob and can be found at the rear of the appliance.
MAINTENANCE CLEANING AND INSPECTION OF VENTING SYSTEM At least once yearly, preferably before the heating season, have the insert and venting system cleaned and inspected by a qualified service person. This will insure proper and safe operation throughout the year. CLEANING THE BURNER TUBES 1. 2. 3. 4. 5. 6. 7. 8. PILOT HOOD Turn off pilot light. Loosen set screw in casting by latch and open door. Remove logs and glowing charcoals. (See Burner orifice Replacement, Pg.
BLOWER CLEANING AND/OR REPLACEMENT Cleaning is recommended at least once yearly or as needed. 1. Disconnect power and turn off gas supply. 2. Unplug blower at molex connector (see “A” below). 3. Remove two screws on back plate of blower compartment. 4. Slide blower compartment away from stove. 5. Vacuum or brush off dust and lint from fan blades. For Replacement: Follow instructions above for removal of blower. Re-install new blower: 1. Key two fingers on the blower compartment into slots on stove back. 2.
SCHEMATICS B Orange=O Black=B White=W Red=R Green=G O Page 43
SNAP DISC REPLACEMENT 1. Disconnect power from unit and turn off gas supply. 2. Remove four screws as shown in figure below and take off rear heatshield. 3. Remove all wires attached to snap disc. 4. Remove set screws holding snap disc in place. 5. Replace in reverse order.
ACCESSORIES These may be ordered through your Quadra-Fire dealer.
PILOT REPLACEMENT INSTRUCTIONS 1) If log set is installed, remove the top logs, center log, ember nuggets and left base log. If log set is not installed remove only left base log. 2) Remove six #8/32 screws that hold the center burner pan in place. Lift burner pan out of firebox and set aside. 3) Remove two #8/32 screws that hold pilot assembly plate to the pilot tower. 4) Disconnect igniter wire from piezo.
FLAME TROUBLESHOOTING NOTE: It is important to understand that the flame and glow in this appliance was designed to resemble a matured wood flame. The amount of charcoal nuggets and glowing ember limit the amount of flame height attainable. This appliance will not have the typical tall yellow gas unit flames. (Avg. flame height 35”). This stove will take 20-30 minutes for the flame to establish itself.
Flame Troubleshooting, cont. 2. If vertically vented, a restrictor strap is required to reduce the volume of combustion air, which in turn will raise the flame height. Restrictor Strap NOTE: This plate rests on damper shaft. FIG. B 3. If vented vertically with a horizontal run included; determine if the rise to run is close to the venting graft maximum, i.e. you are using the maximum horizontal for the amount of vertical.
PILOT TROUBLESHOOTING A. B. C. Pilot won’t light 1. Make sure valve setting is in the pilot position. 2. Check for spark at igniter. a. If no spark: 1. Check the wiring between the piezo and the igniter. Wire may be looped and be sparking to stove body. If so, move wiring. Check tightness of piezo mounting nut. If this does not remedy the problem you may have a faulty piezo or cracked ceramic on the electrode. 2. Call your Quadra-Fire dealer. b. If there is a spark: 1.
FLAMES Thermopile Pilot Hood (Millivolt Generator) Thermocouple PILOT ASSEMBLY SHOWING FLAME PROPERLY ADJUSTED.
NorthAmerica’sBest GAS STOVE LIMITED LIFETIME WARRANTY Aladdin Hearth Products, warrants this gas heating appliance to the original purchaser for the lifetime of the appliance, to be free from defects in material and workmanship. This warranty gives you specific legal rights; you may have other rights which may vary from state to state. This limited Lifetime Warranty covers items such as but not limited to combustion chambers, burners, gas logs, and gold plating.
