Firegear KALEA BAY, Installation And Operating Instructions Manual

Page 1: ... MODELS Natural Gas Description OFP 36LECO NLED 36 Open Front Fireplace OFP 48LECO NLED 48 Open Front Fireplace OFP 60LECO NLED 60 Open Front Fireplace OFP 72LECO NLED 72 Open Front Fireplace Kalea Bay Outdoor Gas Fireplace with LED Lighting Installation and Operating Instructions LED MODEL DO NOT DISCARD THIS MANUAL HAS IMPORTANT OPERATING AND MANTENANCE INSTRUCTIONS LEAVE WITH THE HOMEOWNER MODE...

Page 2: ... use gasoline or other flammable vapors and liquids in the vicinity of this or other appliances If you smell gas 1 Shut off gas to the appliance 2 Extinguish any open flame 3 If odor continues leave the area immediately 4 After leaving the area call your gas supplier or fire department DANGER FIRE OR EXPLOSION HAZARD HOT GLASS WILL CAUSE BURNS DO NOT TOUCH GLASS UNTIL COOLED NEVER ALLOW CHILDREN T...

Page 3: ...he fireplace Heavy rains high humidity and the presence of moisture can contribute to this process 1 This appliance is configured from the factory only as Natural gas It can be converted to LP gas 2 Do not place Propane LP supply tanks inside any unapproved structures Locate propane tanks outdoors if unsure 3 This fireplace is to be used only outdoors in a well ventilated space and shall not be us...

Page 4: ... Windshield Installation 27 Flame Height 28 Operation 29 Lighting Instructions 29 Replacement Parts 30 Replacement Parts List 31 Gas Conversion Natural Gas to LP Gas 32 34 Fireplace Maintenance 35 Troubleshooting 36 37 Optional Accessories 38 Warranty 39 TABLE OF CONTENTS Fuels used in gas fired appliances and the products of combustion such as fuels contain chemicals known to cause cancer birth d...

Page 5: ...fireplace is designed to have glass media covering the burner trough so the burner tube is not visible Media is NOT provided and must be purchased separately When installing media use minimum of to diameter Firegear Outdoors glass to fill the burner trough After the burner trough is covered you are permitted to fill the remaining area in the burner pan DO NOT COVER THE IGNITION HOOD WITH ANY ROCK ...

Page 6: ...for a flush fit up to the opening of the fireplace DO NOT PROTRUDE INTO THE FIREPLACE OPENING WITH CEMENT BOARD Fig 1 Close up view of inlet gas connection with shut off valve VENTILATION FOR NON COMBUSTIBLE ENCLOSURE Fireplaces are subjected to many outdoor elements such as rain snow wind heat or cold A minimum of 18 square inches of cross ventilation 2 sides is required to keep the components in...

Page 7: ...ane Gas should be done by a qualified installer service agency or gas supplier This appliance must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than psig 3 5kPa WARNING Proper clearances from combustible construction materials must be maintained from all sides top and...

Page 8: ...CIFICATIONS Fig 4 The fireplace ships on a wooden skid Remove the screws as shown and lift fireplace off of skid Note Number of screws vary with model size Table 1 Fireplace specifications and conversion kits NG Models NG Factory Orifice NG Btu s High NG Btu s Low NG Low Rate Screw LP Conversion Kit LP Factory Orifice LP Low Rate Screw OFP 36LECO NLED 41 31 000 9 08 kW 18 500 5 42 kW 44 OFP 36LECO...

Page 9: ... specific pipe sizes required for the amount of BTU s for a new gas line installations If you are using an existing gas line you must take into consideration the existing gas line capacities to ensure you will have proper pressure This chart is for reference only we recommend you consult with a Licensed Plumber Gas Fitter or NFPA54 National Fuel Gas Code current edition for more details Length of ...

Page 10: ...pecific sizes 1 77145A Windshield Fastener Bag includes 1 Left LED glass clip 77157 1 Right LED glass clip 77156 1 Left Std glass clip 77155 1 Right Std glass clip 77154 7 hood screws 77129 1 It is important to understand that when installing this outdoor appliance the installation must follow ANSI standards as described below AN OUTDOOR SPACE IS DEFINED AS FOLLOWS PER ANSI Z21 97 Outdoor spaces A...

Page 11: ...tible Side Wall I Clearance To Combustible Ceiling OFP 36LECO NLED 40 36 33 16 16 11 10 6 46 OFP 48LECO NLED 52 48 33 16 16 11 10 6 46 OFP 60LECO NLED 64 60 33 16 16 11 10 6 46 OFP 72LECO NLED 76 72 33 16 16 11 10 6 46 Fig 6 Single sided fireplace clearance to combustibles See Table 3 Fig 7 Open front fireplace mantel clearances FRONT VIEW TOP VIEW END VIEW E E C 2 20 F D A B G Bottom Finish Fin H...

Page 12: ...ING DIMENSIONS WITH METAL STUDS Table 5 Fireplace framing dimensions NOTE This fireplace requires metal studs for framing WOOD STUDS ARE NOT PERMITTED NOTE This outdoor fireplace is not a load bearing fireplace All finishing materials must be supported by the surrounding structure and not rely on the fireplace itself Metal Studs Metal Studs A B Metal studs shown in gray Bottom Support Fin Hood C M...

Page 13: ...standards as described below AN OUTDOOR SPACE IS DEFINED AS FOLLOWS PER ANSI Z21 97 Outdoor spaces An appliance is considered to be outdoors if installed with shelter no more inclusive than a With walls on all sides but with no over head cover b Within a partial enclosure which includes an overhead cover and no more than two side walls These side walls may be parallel as in a breezeway or at right...

Page 14: ... Wall I Clearance To Combustible Ceiling OFP 36LECO NLED 40 36 33 16 16 11 10 36 46 OFP 48LECO NLED 52 48 33 16 16 11 10 36 46 OFP 60LECO NLED 64 60 33 16 16 11 10 36 46 OFP 72LECO NLED 76 72 33 16 16 11 10 36 46 Fig 10 See through fireplace clearance to combustibles See Table 6 I H END VIEW S I D E W A L L CEILING FLOOR 11 Back Front This fireplace ships from the factory as a single sided firepla...

Page 15: ...NG DIMENSIONS WITH METAL STUDS Table 7 Fireplace framing dimensions NOTE This outdoor fireplace is not a load bearing fireplace All finishing materials must be supported by the surrounding structure and not rely on the fireplace itself Metal Studs A B Metal studs shown in gray Bottom Support Fin Hood C Metal Studs Metal Studs Top view showing lip using non combustible facing material at front face...

Page 16: ... is not a requirement however with the gang box on the opposite side of inlet will create more room for LED installation Fig 15 shows GFCI gang box installed Step 2 Find mounting location for the GFCI gang box Fig 14 shows flat area underneath burner pan Mount box underneath the burner pan below the square cutout hole area Fig 15 shows the GFCI outlet double gang junction box with a weatherproof c...

Page 17: ...ng them down through the metal bridges as shown in Fig 17 Install 1 clip on the left and 1 clip on the right side of the inner fireplace side panel Note If you are preparing a see through fireplace you will install a total of 8 glass clips two for each open side The additional clips are supplied with the see through conversion kit Fig 17 Shows both glass clips being installed on right side of fire...

Page 18: ...r LED light strip and channel the same direction Fig 20 Installing LED lights and channel Fig 21 LED installed in retainer clip inside fireplace LED LIGHTING INSTALLATION Step 5 Remove the LED right channel assembly from the carton The front of the channel has a shield facing the front with the LED wire hanging on the right side See Figs 19 21 for details Note If you are installing into a see thro...

Page 19: ...he female connector in one direction Once locked in position screw the threaded cap of the female connector securely over the male connector Step 9 Attach 77110 to 77111 using the molex connectors After connecting the LED lights into the 77111 wire harness insert the 12 volt adapter 77102 with terminals into the red black wires of LED wire harness Plug the 12 volt adapter into the 120VAC GFCI box ...

Page 20: ...if needed Ensure to match the wires with the labels for each switch when reattaching Step 14 Remove the 8 PIN module wire harness 77161 from the components part box Locate the 8 PIN male connector from the valve box under the fireplace and connect it to the 8 PIN female end of the wire harness Connectors only attach one way press together until it snap locks into place See Fig 26 page 21 for detai...

Page 21: ... AF4000ADP48EXT 77102 77113 77159 77111 LED Tray Assy 77110 77102 D e t a i l o f Hidden wires Fig 26 Overview of fireplace wiring to control box Note The fireplace is provided with 10 feet of wire If you require a longer length an optional 10 foot wire harness 77161 77111 are available in replacemet parts section LED LIGHTING INSTALLATION ...

Page 22: ...box REPRESENTS COMPONENTS INSIDE LED CONTROLLER BOX 12VDC adapter inside a weatherproof box REPRESENTS COMPONENTS INSIDE FIREPLACE AF 4000ADP24 7 5VCD adapter powers gas valve system Brown Blue Yellow Black Red Note If using single sided fireplace only one LED connection will be used AF 4000ADP48EXT Fig 27 This wiring diagram shows the LED circuit in relationship to the IPI gas valve control syste...

Page 23: ...ET OUTLET PILOT TUBE S I SWITCHES POWER MOTOR COMM BATT V BRONZE INSULATED WIRE BLACK WIRE BRASS WIRE GROUND MOTOR DRIVE WIRES TO 120VAC POWER SWITCHES MOUNTED IN RGB CONTROL ASSEMBLEY LOW RATE SET SCREW Fig 28 This wiring diagram shows the components inside the valve box The dotted line box shows the components external of the valve box GAS VALVE WIRING DIAGRAM ...

Page 24: ...nition hole as shown in Fig 30 The ignition screen sit on top of the burner tube Fig 30 Installing ignition screen Step 22 Place pilot hood on top of the pilot box and ensure if sits flat providing ventilation for the pilot at the front edge of the burner pan See Figs 31 and 32 Fig 31 Pilot hood installing over top of pilot box NOTE The pilot hood will have a plastic film that must be removed befo...

Page 25: ...as shown is Figs 34 36 Place media fireglass into the trough area first as shown in Fig 35 Use the remaining media to fill the burner pan equally on both sides Install only one layer over top of the ignition screen Fig 32 just enough to camoflauge it Keep media in burner pan the same level as the trough to allow the burner area to appear as one complete burner pan IMPORTANT Media can only be place...

Page 26: ...rews to secure the hood to the fireplace except the 72 inch model which uses seven 7 screws 77129 8 32x1 2 stainless pan head to secure the hood The hood protrudes 1 inch from fireplace opening Fig 37 shows hole location and installation process for hood installation The protruding area of the hood is to be angled downward for proper installation see Hood Detail below Fig 37 Installing hood s on t...

Page 27: ...lip supporting the glass at the top and bottom as you handle it See Fig 39 As the glass enters the clip the bottom edge of the glass will rest in place on the bottom of the clip Install the second glass pane in the same manner as described in Fig 39 Both glass panels should be level when installed Center glass between clips after installation Step 1 Step 2 Front of Fireplace LED HOT GLASS WILL CAU...

Page 28: ...y code Press any button on the transmitter within 60 seconds The code is accepted when you hear 4 short beeps in rapid succession Security codes will be retained in memory indefinitely if power is removed Note Control module accepts a total of three 3 wireless transmitters 2 To Clear Codes Press and hold learn switch on for 6 seconds to clear all transmitter security codes retained in memory Codes...

Page 29: ...not burn any solid fuels in this appliance LIGHTING INSTRUCTIONS READ ALL WARNING AND SAFETY INFORMATION ABOVE BEFORE ATTEMPTING TO LIGHT FIREPLACE Turn ON main gas supply and check all fittings and connections for leaks with a soap and water solution Fig 42 Control panel rocker switches RGB DIMMER Mounting plate under switch cover LED ON OFF ON OFF LOW HIGH LEARN CONT PILOT 5 5 8 143mm 5 5 8 143m...

Page 30: ...place REV B Page 30 Glass Panel 1 2 Drawings Not to Scale 5 11 REPLACEMENT PARTS Not all parts are shown but all are listed on replacement parts page 9 S I SWITCHES POWER MOTOR COMM BATT V 16 18 19 7 4 3 6 8 10 15 14 17 12 20 13 ...

Page 31: ...des 8 pin wire harness ECO VK ECOMOD WH 11 Tempered Glass Windshield for 36 model x 8 x 35 KB 36 73120 11 Tempered Glass Windshield for 48 model x 8 x 47 KB 48 74120 11 Tempered Glass Windshield for 60 model x 8 x 59 KB 60 75120 11 Tempered Glass Windshield for 72 model x 8 x 71 KB 72 76120 12 Glass Clips 2 supports for LED channel Right 77156 Left 77157 13 Glass Clips 2 supports for glass panel o...

Page 32: ...he new OAS LP orifice per Table 1 Ensure to use gas rated Teflon tape around the threads or pipe compound Check for leaks after conversion is complete Fig 2 Changing main burner orifice Step 4 Locate the gas regulator the opposite side of the valve box Using a regular size flat bladed screwdriver remove the aluminum cap and washer from the regulator See Fig 2 Table 1 Reference information Fig 4 Re...

Page 33: ... Step 7 In the center of the burner pan where the pilot is located See Fig 6 remove the pilot head Note Some media may need to be removed to gain access Fig 6 Show pilot assembly under the pilot hood Step 8 Lift pull the pilot head straight up and out of the pilot assembly If pilot head does not move then pull the wire clip under the head with a small screwdriver or needle nose pliers then lift th...

Page 34: ... of low rate set screw Step 11 Remove the low rate set screw with a flat bladed screwdriver turning the screw counter clockwise The set screw has a rubber O ring on the outer portion of the screw as a result the screw will rotate only 3 4 revolutions and not unscrew any farther Note If you drop the low rate screw inside the valve area you can retrieve it through the access door of the valve box St...

Page 35: ... clean mix several drops of dish washing liquid into a bucket of hot water The dish soap assists in breaking up the soot and removing it from the metal CAUTION Ensure fireplace is cool to touch and gas is turned OFF before cleaning A Dip a scrubbing sponge into the soapy water and wipe it back and forth over the soot deposits This breaks off the majority of the soot from the metallic surface B Spr...

Page 36: ...in my Fireplace 1 Excess dust sand material from media may be blocking the weep holes to relieve water Remove all media and unplug weep holes Clean or install new media free of dust and dirt 2 Ensure fire pit enclosure has proper drainage for water and proper ventilation to dry out 3 Recommend to purchase a cover if applicable to keep excessive water out of the fire pit Whistling Noises 1 Check me...

Page 37: ...ressed the ON OFF button 6 times within 2 minutes causing the step motor to turn gas valve to OFF position Corrective Action Press OFF button to clear After 5 minutes the beeping will stop then retry Sensor Safety Error Four short beeps every one second constant beeping Cause Pilot flame sensor voltage too high ground circuit not properly connected pilot ground wire loose or not connected or motor...

Page 38: ...page 32 in manual Wireless Wall Switches Model 1322 WT Wireless wall switch ON OFF HI LO Model 1001D ATX Wireless wall switch ON OFF ONLY Model TM R AF1TX 4 Button Wall Timer 30 60 120 OFF LED Extension Wire Model 77111 6 pin LED extension wire harness to move control box further distance from fireplace Module Extension Wire Model 77161 8 pin Module extension wire harness to move control box furth...

Page 39: ...EAR WARRANTY REFRACTORY GAS LOG SETS FIVE 5 YEAR WARRANTY READY TO FINISH ANF FIRE PIT ENCLOSURES FIVE 5 YEAR WARRANTY SKYTECH MANUACFTURED OPTIONAL CONTROLS OUTDOOR FIREPLACE KALEA BAY LIFETIME WARRANTY CONSTRUCTION AND MANUFACTURER DEFECTS LIFETIME WARRANTY STAINLESS STEEL COMPONENTS FIVE 5 YEAR WARRANTY GAS VALVE PILOT ASSEMBLY POWER SUPPLY CONTROLS FIVE 5 YEAR WARRANTY SKYTECH MANUACFTURED OPT...

Page 40: ...LACE KALEA BAY LIFETIME WARRANTY CONSTRUCTION AND MANUFACTURER DEFECTS LIFETIME WARRANTY STAINLESS STEEL COMPONENTS TWO 2 YEAR WARRANTY GAS VALVE PILOT ASSEMBLY POWER SUPPLY CONTROLS TWO 2 YEAR WARRANTY SKYTECH MANUACFTURED OPTIONAL CONTROLS SANCTUARY SERIES GFRC FIRE FEATURES THREE 3 YEAR WARRANTY GFRC STRUCTURE REFER TO THE APPROPRIATE BURNER SYSTEM FOR WARRANTY WARRANTY COVERS MANUFACTURING DEF...

Page 41: ...pair the defect on warranty parts to and from the factory will be the responsibility of the owner We will not be responsible for labor charges and or damage incurred in installation repair and replacement Firegear is not responsible for Issues related to gas or electrical installation The Limited Warranty is voided if not assembled installed and operated as intended This Limited Warranty does not ...

Page 42: ...mages Our maximum liability is limited to the purchase price of the purchased units Some states do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you We do not authorize any person or company to assume for it any other obligation or liability in connection with the sale installation use removal return or replacement of ...

Page 43: ...Kalea Bay LED Outdoor Fireplace REV B Page 43 Notes ...

Page 44: ...__ 2 Serial Number ___________________________ 3 How long is the gas line run Nat Gas ____ LP Gas ____ 4 What size is gas line _____ 5 Inlet Gas Pressure _____WC Manifold Gas Pressure _____ WC 6 What type of media are you using __________________ 7 Review the troubleshooting section in the installation manual 8 What are the symptoms Please be prepared to explain 9 Be prepared to send photos to us ...