Lennox International Inc BV4000C Catalyst Plugging, Catalyst Deactivation, Catalyst Substrate

TROUBLESHOOTING

CATALYST PLUGGING

1.Burning materials that produce a lot of char and fly ash. Do not burn materials such as garbage, gift wrap, card- board, etc.

2.Burning wet pitchy woods or burning large loads of small diameter wood with the combustor in the operation posi- tion (without light-off taking place). Burn proper fuel only. Do not close bypass until temperatures are high enough to initiate light off.

CATALYST DEACTIVATION

1.Burning large quantities of trash, pressure-treated lum- ber or painted woods, etc. will deactivate the catalyst. Burn proper fuels only. See Catalyst Replacement, page 19.

CATALYST SUBSTRATE CRACKING

1.Normal operation, as long as combustor remains intact. If cracking causes large pieces to fall out, re- place combustor.

2.Mishandling or abuse. Handle with care.

3.Warped housing (see Overfiring, this page).

CATALYST SUBSTRATE

1.Extreme thermal shock. Combustor is being worked too hard.

2.Excessive draft. Correct installation. See Draft Re- quirements, page 6

CATALYST PEELING

Extreme Temperatures (over-firing) at combustor surface can cause the catalyst to peel. Some minor peeling does not affect function. Severe peeling would close cell openings and cause a plugging problem. If peeling is severe, replace com- bustor. Do not overfire appliance. See Overfiring, this page.

TAR AND LIQUID CREOSOTE LEAKING FROM METAL FLUE JOINTS

1.No chimney cap on chimney. Install cap.

2.Metal flue assembled improperly. Top flue sections should be inserted into lower flue sections.

DENCE SMOKE LEAVING CHIMNEY

1.Water vapor (on cold still days water vapor may be mis- taken for smoke). Water vapor is normal and should be of little concern.

2.Wet, pitchy woods being burned. Burn dry seasoned wood only.

3.Bypass in open position. Close bypass.

4.Combustor not functioning. See Catalyst Replacement, page 19.

OVERFIRING

If any part of the appliance glows, it is overfiring. Other symptoms may include: Cracking, warping or burning out of components, catalytic combustor may deteriorate, gold doors may turn color, stove glass may develop a haze which will not come off with cleaning, firebox baffle plate (tunnel baffle) may warp, etc.

Overfiring of a fireplace insert is a condition where ex- cessive temperatures are reached, beyond the design capabilities of the appliance. The damage that occurs from overfiring is not covered under the manufacturers limited warranty. The following are a few conditions that should be evaluated and (corrected if necessary) if an overfiring condition is suspected:

Overfiring Caused From Improper Installation

The venting system must satisfy the draft Requirements of the appliance. The appliance is merely one component of a larger system. The other equally important compo- nent is the venting system, which is necessary for achieving the required flow of combustion air to the fire chamber and for safely removing unwanted combustion byproducts from the appliance. If the venting system’s de- sign does not promote these ends, the system may not function properly, which may create performance prob- lems as well as may be a safety hazard. To ensure that all installation requirements have been met as outlined in the installation manual. The chimney should be clean and in good repair. A draft test should be performed to deter- mine if the draft requirements of the appliance are being met. A draft gauge should read between .05 and .07 inches water column (W.C.I.). Excessive draft (above .07 W.C.I.) will allow too much combustion air to be pulled into the firebox, which results in hotter burns. Too little draft (below .05 W.C.I.) will not allow enough combustion air delivery to maintain a fire well or cause performance problems such as smoking (this may result in improper operation of appliance, i.e. will not maintain fire well unless catalytic bypass is left open, or with fuel door left open – see Operation).

Overfiring Caused From Improper Operation

Never burn the appliance with the fuel door open or ajar, the ash dump cover off or the ash drawer open. Never burn the stove with the bypass handle in the open position once the fire has been established or the air control in the "high" position for extended periods.

Overfiring Caused From Improper Maintenance Strictly adhere to all maintenance requirements at frequent intervals as prescribed in this manual in- cluding cleaning of flue and fireplace insert. Should the fuel door, ash dump or glass gaskets become worn or damaged, they should be replaced.

Overfiring Caused From Improper Fuel

This appliance is approved for use with natural dry well seasoned wood only (consult your dealer for approved fuels in your area). Do not burn garbage, particleboard scraps, or pressed logs using bonding agents because they can produce conditions that will deteriorate metal. Green or uncured wood does not work well as fuel, and can cause increased creosote buildups. Do not overload or use kindling wood or mill ends as primary fuel.

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