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Duluth Forge FDF400T-ZC Series User Manual

Duluth Forge FDF400T-ZC Series
32 pages
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VENT-FREE GAS SYSTEM
OWNER'S OPERATION
AND INSTALLATION
MANUAL
MODELS
FDF400T-ZC SERIES
PFS
®
US
WARNING: If the information in this manual is not
followed exactly, a re or explosion may result causing
property damage, personal injury or loss of life.
Do not store or use gasoline or other ammable va-
pors and liquids in the vicinity of this or any other
appliance.
WHAT TO DO IF YOU SMELL GAS
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 neighbors
phone. Follow the gas suppliers instructions.
If you cannot reach your gas supplier, call the re
department.
Installation and service must be performed by a quali-
ed installer, service agency or the gas supplier.
WARNING: This appliance is equipped for natural and
propane/LP gas. Field conversion is not permitted other
than between natural or propane/LP gases.
Questions, problems, missing parts? Before returning to your retailer, call
our customer service department at 1-855-607-6557, 8:00 am - 4:30 pm EST,
Monday through Friday or email info@factorybuysdirect.com
Question and Answer IconNeed help?

Do you have a question about the Duluth Forge FDF400T-ZC Series and is the answer not in the manual?

Duluth Forge FDF400T-ZC Series Specifications

General IconGeneral
ModelFDF400T-ZC Series
Ignition SystemElectronic Ignition
MaterialSteel
FinishBlack
Log MaterialCeramic Fiber
TypeVent-Free Gas Fireplace
Fuel TypeNatural Gas or Liquid Propane
Warranty1 Year Limited Warranty

Summary

Safety Precautions and Warnings

General Safety Precautions

Essential safety warnings regarding operation, installation, and potential hazards.

Carbon Monoxide Awareness

Information on carbon monoxide poisoning symptoms and risks associated with gas heaters.

Gas Properties Explained

Details on the odorless nature of natural and propane/LP gases and the added odorant.

Specifications and Features

Product Specifications Table

Technical details including input ratings, pressure, dimensions, and weight for the FDF400T-ZC model.

Qualified Installing Agency Definition

Criteria and responsibilities for a qualified installation professional for gas appliances.

Key Heater Features

Overview of safety pilot, piezo ignition, thermostat control, and dual gas options.

Product Identification and Unpacking

Fireplace Insert Components Diagram

Diagram identifying main external parts of the vent-free fireplace insert.

Heater Unpacking Procedure

Step-by-step guide for safely removing the heater from its packaging.

Adhering to Local Regulations

Guidance on following local codes and specific Massachusetts installation requirements.

Water Vapor and Ventilation

Managing Water Vapor Output

Information on water vapor as a byproduct of combustion and methods to manage it.

Combustion Air Requirements

Critical warnings and guidelines for ensuring adequate air for safe operation and preventing hazards.

Ventilation Air Options

Methods for providing ventilation air from inside or outside the building with diagrams.

Installation Procedures

Heater Installation Precautions

Critical warnings and cautions for proper installation, including location, preparation, and clearances.

Gas Type Verification

Instructions to ensure the correct gas type (Natural or Propane/LP) is used for the heater.

Gas Selection and Regulator Setup

Procedure for selecting gas type and configuring the regulator for installation, including color coding.

Connecting to Gas Supply

Detailed steps for connecting the heater to propane/LP or natural gas supplies, including regulator installation.

Clearances to Combustibles

Mandatory clearances from the heater to combustible materials, walls, and ceiling.

Mantel Assembly and Placement

Instructions for assembling and installing a mantel before connecting the gas supply.

Built-in Fireplace Installation Warnings

Precautions for installing the fireplace into a framed enclosure, including material placement and openings.

Framing and Rough Opening

Dimensions and guidelines for creating the rough opening for wall and corner installations.

Standoff Bracket Installation

Procedure for installing standoff brackets for proper heater placement within the opening.

Gas Supply Connection Requirements

Essential warnings and cautions for connecting the gas supply safely and correctly, including pipe types and pressure.

Required Installation Components

List of parts and materials needed for safe and proper gas supply connection, such as shutoff valves and sealant.

Inlet Pipe Diameters and Gas Diagrams

Guidelines for pipe sizing, gas connection layouts, and external regulator installation with diagrams.

Sediment Trap and Leak Testing

Procedure for installing a sediment trap and the critical importance of leak testing all gas connections.

Leak Detection Procedures

Methods for safely checking gas supply and heater connections for leaks using detection fluid.

Pressure Testing Guidelines

Procedures for pressure testing gas supply piping and heater connections to ensure integrity.

Installing Logs and Batteries

Log Placement and Safety

Instructions for correctly installing logs, checking flame patterns, and avoiding soot formation.

Log Installation Steps

Step-by-step guide for installing logs #4, #5, and #6 with diagrams.

Battery Installation Procedure

Guidance on installing AAA batteries for the ignitor, including polarity and safety precautions.

Operation and Lighting

Safety Before Lighting

Critical safety warnings and procedures to follow before attempting to light the heater, including gas leak detection.

Lighting Instructions

Step-by-step guide for safely lighting the heater pilot and main burner, including control locations.

Turning Off the Appliance

Procedure for safely shutting down the heater and its burner, including pilot-only operation.

Manual Lighting Procedure

Alternative method for lighting the pilot using a match if the ignitor fails.

Inspecting Burners

Pilot Flame Pattern Inspection

How to identify correct and incorrect pilot flame patterns and their implications for heater function.

Burner Flame Pattern Inspection

Guidance on checking the main burner flame pattern for proper operation and potential issues like sooting.

Burner Primary Air Holes Maintenance

Maintenance of primary air holes to prevent soot formation and ensure proper combustion.

Care and Maintenance

Main Burner Maintenance

Instructions for inspecting and cleaning the main burner flame holes for optimal performance.

Burner and Pilot Cleaning

Procedure for cleaning the burner injector holder and pilot air inlet holes using compressed air.

ODS/Pilot and Cabinet Cleaning

Guidelines for cleaning the ODS/pilot assembly and the heater cabinet to maintain functionality.

Log Care and Replacement

Information on cleaning logs and criteria for replacing logs if broken or chipped.

Troubleshooting Guide

Gas Leak and Safety Warnings

Immediate actions if gas is smelled and warnings for qualified service technicians during troubleshooting.

Pilot Ignition Issues

Troubleshooting steps for when the natural gas pilot will not light due to inlet pressure exceeding limits.

Ignitor and Pilot Ignition Problems

Diagnosing issues with ignitor spark generation and pilot flame ignition.

Pilot Flame Stability

Troubleshooting why the pilot flame goes out after the control knob is released, often due to thermocouple or pressure.

Burner Operation Issues

Diagnosing problems like burner not lighting, delayed ignition, backfiring, and high yellow flame.

Odor and Noise Troubleshooting

Addressing issues related to gas odor, smoke, and whistling noises during heater operation.

Miscellaneous Troubleshooting

Resolving issues such as clicking noises, white powder residue, unwanted odors, unit shutdown, and condensation.

Parts Information

Model FDF400T-ZC Parts Diagram

Exploded view diagram identifying all replaceable parts of the FDF400T-ZC model heater.

Replaceable Parts List

Detailed list of part numbers, descriptions, and quantities for ordering replacement components.

Replacement Parts and Accessories

Parts Under Warranty Information

How to obtain warranty service and required information for claims, including contact details.

Available Accessories

Information on purchasing optional accessories like shutoff valves and installation kits for the heater.

Service Hints and Technical Support

Low Gas Pressure Issues

Common problems and advice when gas pressure is too low, affecting pilot and burner operation.

Technical Service Contact

Contact information for customer support for installation, operation, or troubleshooting inquiries.

Warranty Information

Warranty Registration and Information

Instructions for keeping and registering the warranty for service verification and product support.

Limited Warranties (New & Reconditioned)

Details of standard and limited warranties for new and factory reconditioned products.

Terms Common to All Warranties

General terms and conditions applicable to all provided warranties, including limitations and exclusions.

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