ACR STOVES Malvern II Classic User manual

Malvern II Classic
Multifuel Stove Model • MAL2CL
To be retained by the user for future reference
Thank you for purchasing an ACR Heat Products stove
TECHNICAL MANUAL
MAL2CL 0101 • Version 1 Date 18/07/16
Serial Number:
MULTI
FUEL
SMOKE
EXEMPT
AIRWASH
SYSTEM
10
YEAR
10
YEAR
WARRANTY
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IMPORTANT INFORMATION
• Before installation and/or use of this
appliance please read these instructions
carefully to ensure that all requirements are
fully understood.
• This appliance must be installed by a
registered engineer, or approved by building
control, failure to do so may endanger life and
property.
• All the instructions in this manual should work
in conjuction with building regulations
document J, if there is a variation the most
stringent requirement should be adhered to.
• The installation of this appliance must comply
with current Building Regulations and local
regulations, including those referring to
national and European standards need to be
complied with when installing the appliance.
• Do not operate this appliance if it becomes
damaged.
• Improper use, maintenance or fitting parts
other than those approved by the
manufacturer could lead to the appliance
becoming damaged or unsafe which in turn
could lead to personal injury or damage to
the property and will void the warranty.
• The appliance must not be modified in
anyway unless authorised by ACR Heat
Products Ltd.
• The appliance should be inspected regularly
to ensure the airways are clean and free from
obstruction and the chimney swept at least
once a year.
• The external surfaces of this appliance will be
very hot to the touch when in operation and
due care will need to be taken when
operating the appliance to ensure safety. A
fire guard should be fitted if it is likely that the
elderly, infirm or children may come into
contact with the appliance.
• This appliance has been designed for
intermittent operation.
• This appliance must not be used as an
incinerator.
• Each installation is unique to the property, the
information contained in this manual may not
give exact installation requirements for your
installation.
• The installation must comply with Building
Regulations, European Standards and Local
authority bylaws.
Asbestos
This appliance contains no asbestos, if there is
the possibility of disturbing any asbestos in the
installation of this appliance then specialist
advise must be sought and appropriate
precautions taken.
Metal Parts
This appliance may contain sharp metal edges,
take care when installing or servicing this
appliance to avoid personal injury. Please use
appropriate personal protective equipment at
all times.
To ensure that you gain the most from your purchase, please take a few minutes
to read through this manual before lighting the appliance for the first time.
Since April 2002 only registered competent installers can install solid fuel appliances. Installations
carried out by non-registered installers must be inspected by local authority building control.
For more information please contact hetas at: www.hetas.co.uk or telephone: [phone]
Before installation, please ensure that the correct model has been supplied.
Please make a note of the serial number of your appliance in the space provided on the front cover
of this manual as this will be requested if you require technical assistance in the future.
Please also ensure that the commissioning checklist at the rear of the manual is completed in full.
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Malvern II Classic Specifications
*** Please note that Building Regulations Document J advises that additional permanent air supply is
required for appliances with an output of above 5Kw.
With modern properties additional air may be required as Document J suggests that adequate air
would be a benefit.
• If design air permeability ≥5.0m³/ (h.m²) then 550mm²/kW of appliance rated output above 5kW
Or
• If design air permeability ≤5.0m³/ (h.m²) then 550mm²/kW of appliance rated output
• If in doubt, please consult your registered installer for advice.
Removable 80mm direct air collar at 120mm from hearth level.
If installing into a room containing an extractor fan, please ensure that the relevant tests are
carried out according to Document J of the building regulations.
Nominal heat output 5 kW - Wood 5 kW - Maxibrite
Chimney draft required 12Pa
Height 551 mm
Width 491 mm
Depth 331 mm
Weight 82 kg
Air Requirement N/A ***
Flue Mass Gas Flow 3.8 g/s - Wood 3.3 g/s - Maxibrite
CO @ 13% O20.09 Wood vol % 0.07 Maxibrite vol%
Mean Flue Gas Temperature 228°C - Wood 270°C - Maxibrite
Efficiency 84.3% - Wood 82.3% - Maxibrite
Mean CnHm @13%O2 Wood - 102Nmg/M3 Maxibrite - 26Nmg/M3
Mean NOx @13%O2 Wood -113Nmg/M3 Maxibrite - 136Nmg/M3
DIN Plus Dust @13%O2 Wood -19Nmg/M3 Maxibrite -18 Nmg/M3
Log Length Up To 350 mm
435
491
441
551
110
331
253
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The Clean Air Act 1993 and Smoke Control Areas
SMOKE
EXEMPT
Under the Clean Air Act local authorities
may declare the whole or part of the
district of the authority to be a smoke
control area. It is an offence to emit
smoke from a chimney of a building,
from a furnace or from any fixed boiler if
located in a designated smoke control
area. It is also an offence to acquire an
"unauthorised fuel" for use within a
smoke control area unless it is used in
an "exempt" appliance ("exempted"
from the controls which generally apply
in the smoke control area).
The Secretary of State for Environment,
Food and Rural Affairs has powers
under the Act to authorise smokeless
fuels or exempt appliances for use in
smoke control areas in England. In
Scotland and Wales this power rests
with Ministers in the devolved
administrations for those countries.
Separate legislation, the Clean Air
(Northern Ireland) Order 1981, applies in
Northern Ireland. Therefore it is a
requirement that fuels burnt or obtained
for use in smoke control areas have
been "authorised" in Regulations and
that appliances used to burn solid fuel
in those areas (other than "authorised"
fuels) have been exempted by an Order
made and signed by the Secretary of
State or Minister in the devolved
administrations.
• Malvern II Classic
(MAL2CL) has been
recommended as
suitable for use in
smoke control areas
when burning wood,
as such, when the secondary air
slider is in the closed position it
remains open by 3mm and the
tertiary air control should be fully
open and is prevented from closing
by a screw.
Further information on the requirements
of the Clean Air Act can be found here:
http://smokecontrol.defra.gov.uk
Your local authority is responsible for
implementing the Clean Air Act 1993
including designation and supervision of
smoke control areas and you can
contact them for details of Clean Air Act
requirements.
CO Alarms
It is required by Building Regulations that
whenever a new or replacement
wood/solid fuel or biomass appliance is
installed in a dwelling a carbon monoxide
alarm to BS EN 50292:2002 must be fitted
in the same room as the appliance.
The alarm should be installed according
to the alarms manufacturers instructions
and should not be considered a substitute
for the appliance being installed correctly
and regular maintenance of the appliance
and flue system by a competent person.
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Installation Instructions
Location of the unit
Clearances to non-
combustible materials
There is a recommended minimum
clearance of 150mm at each side of the
appliance. A clearance of 150mm is
required at the back of stove (if the rear
wall has a thickness of 200mm or more
this measurement can be reduced to
50mm) a recommended clearance of
300mm is required above the appliance
for servicing purposes.
Clearances to combustible
materials
There must be a minimum clearance of
550mm at each side and 450mm at the
rear of the appliance from any
combustible materials. If using single
wall flue pipe, there must be a clearance
of at least 3 times the diameter of the
flue pipe (e.g. 125mm diameter pipe =
375mm minimum clearance) from any
combustible materials e.g. wooden
beam.
Curtains and soft furnishings should be
a minimum of 1m away from the
appliance.
Adequate space should be provided for
servicing the appliance.
We do not recommend that televisions
or artwork are positioned above the
appliance.
Please remember that this appliance
has been designed to provide heat and
if installed into a recess enough space
should be left around the appliance to
enable the heat produced to rise and
escape from the recess back into the
room.
Hearth Requirements
The appliance must stand on a level
fireproof hearth with a minimum
thickness of 12mm. The hearth
temperature created by this stove is
below 100˚C. The hearth must protrude
at least 225mm in front of the appliance
and 150mm either side of the appliance.
The appliance shall be installed on a
floor with an adequate load bearing
capacity. If an existing construction
doesn’t meet with prerequisite, suitable
measures (e.g. load distributing plate)
shall be taken to achieve it.
Flue Requirements
The chimney must comply with current
Building Regulations. Provision must be
made to provide access for cleaning the
appliance, the flue gas connector and
the chimney flue.
The flue must be:
In sound condition and provide
sufficient draft (minimum 12pa)
Suitable for use with solid fuel burning
appliances
Be able to clean the entire length of the
flue system without removal of the
appliance
Free from deposits
Well insulated
At least 4m in height
The flue must not be:
Shared with other appliances
Weight bearing on the appliance
A smaller diameter than the appliance
flue collar size (125mm)
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Assembly of the unit
• Remove the internal vermiculite baffle
(for further instruction please see
under maintenance heading).
• Remove the rear metal cut out plate
from the back of the stove
• Remove the rear blanking plate
• Remove the flue spigot from the top
exit by removing the securing bolts
and rope seal
• Refit the rope seal and flue spigot to
the rear exit and secure with the bolts
• Refit the blanking plate to the top exit
using the rope seal and retaining bolts
This appliance is equipped with a pre-fitted manufacturers smoke exempt stop. Under
no circumstances should it be tampered with or removed unless expressly authorised
by a competent person and the appliance is not installed in a smoke exempt area.
If the appliance is to be installed in a non smoke exempt area you can remove the
restricting screw on the secondary air control (on right hand side under the ash lip)
to allow full movement of the secondary air slider.
The appliance is supplied pre-assembled with the flue spigot in the top exit position.
If you intend to install the appliance using a rear flue connection, the blanking plate should be
swapped over as follows:
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Operating your stove
Please note that during the first firing,
we recommend a small fire is lit and
that you slowly increase the
temperature to enable the various
parts to expand normally.
You may also experience fumes and a
haze being given off by the stove during
the first firing and possibly for the next
couple of firings as the paint cures. This
is normal but please ensure that the
room is well ventilated during this
period.
In the rare event of a malfunction due to
overheating or a chimney fire, the air
slides should be shut down completely
and the fuel allowed to burn out. In the
event of a chimney fire, once the air
slides have been closed completely, dial
999 for assistance. If the appliance has
overheated, the appliance and flue will
need to be inspected for any damage
before it can be operated again.
Recommended Fuels
Wood: hardwood such as ash, oak and
beech which have been cut for at least
2 years and stored under shelter. The
logs should have a maximum moisture
content of 20%. Maximum log length
350mm, maximum width 150mm.
Smokeless Fuels: below 20%
Petroleum coke content such as
Anthracite, Phurnacite, Maxibrite
suitable for use with a closed heating
appliance.
Prohibited Fuels
Green wood: i.e wood which is
less than 2 years old with a
moisture content of above 20%
Recovered wood: i.e pallets,
railway sleepers etc. These will
have been chemically treated
and will pollute the atmosphere
and possibly overheat the
appliance.
Housecoal or bituminous coal:
these fuels will soot up the
airways of the stove and possibly
overheat the appliance.
Petroleum based coke: over
20% - this will overheat the
appliance and possibly damage
the unit.
Liquid fuels.
Paraffin fire lighter blocks:
these can cause damage to the
glass of your appliance.
Always check with your
dealer or directly with the
manufacturer as using the
incorrect fuel may invalidate
your guarantee and damage
your appliance.
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Operating your stove
Instructions for use with
wood
• Pull the secondary air slider (on the
right) fully forward and open the
primary air slider (in the middle) fully
by pulling the lever forward.
• The tertiary air slider should be pulled
fully forward (Under the ashlip) at all
times when burning wood.
• Lay firelighters or rolled up news-
papers on the grate and add a small
amount of kindling wood to the top.
Place 1 or 2 small logs on the top.
• Light the newspaper or firelighters
using a long taper and push the door
closed but do not engage the locking
handle fully.
• When the fire is burning fiercely, after a
couple of minutes add more logs and
close the door.
• When the fire has become established,
close the primary air (in the middle)
down by pushing the lever inwards.
• The burning rate can be altered by
moving the secondary air slider (on the
right) - push the lever inwards to close
down and pull outwards to increase
the burn rate.
• Care should be taken to ensure that
the logs are not placed higher than
the log guard allows.
Instructions for use with
smokeless fuel
• Pull the secondary air slider under the
ashlip and open the primary air slider
fully by pulling the lever forward.
• Make sure that the tertiary slider is
fully pushed in.
• Lay firelighters or rolled up
newspapers on the grate and add a
small amount of kindling wood to the
top. Place a small quantity of
smokeless fuel on top.
• Light the newspaper or firelighters
using a long taper and push the door
closed but do not engage the locking
handle fully.
When the fire is burning fiercely, after
a couple of minutes add more
smokeless fuel and close the door.
• When the fire has become established,
close the secondary air down by
pushing the lever inwards.
• The burning rate can be altered by
moving the primary air slide - pull
forward to fully open and push inward
to close down.
• Care should be taken to ensure that
the firebox is not overfilled with
smokeless fuel - it should be no
higher than the log guard.
• This stove features a split log guard to
allow differing loads to be managed.
• Secondary - right
• Primary - middle
• Tertiary - left
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Re-fueling
When refueling the stove always refuel
onto a bed of hot embers, fully open
the secondary and primary air controls
until the new fuel is well alight, before
adjusting the air controls for the desired
setting.
If there is insufficient burning material in
the firebed to light a new fuel charge,
excessive smoke emission can occur.
Refuelling must be carried out onto a
sufficient quantity of glowing embers
and ash that the new fuel charge will
ignite in a reasonable period. If there are
too few embers in the fire bed, add
suitable kindling to prevent excessive
smoke.
Fuel overloading
Never overload the stove - it will work
very well with two medium sized logs.
The amount of fuel specified in this
manual should not be exceeded,
overloading can cause excess smoke.
Daily Maintenance
The ashpan should be checked and
emptied regularly.
• You should never allow the ashes in
the pan to build up to the level of
the grate.
If they are allowed to build up, the grate
will become sandwiched between the
ash below it and above it. This will
overheat the grate and cause distortion
and premature wear.
Operating your stove
Operation with door left open
Operation with the door open can cause
excess smoke. The appliance must not
be operated with the appliance door left
open except as directed in the
instructions.
Air controls left open
Operation with the air controls or
appliance dampers open fully can cause
damage to the appliance. The appliance
must not be operated with air controls,
appliance dampers or door left open
except as directed in the instructions.
• Never leave the stove unattended
until the new fuel is well alight.
• Persistent fume emission is
dangerous and must be
investigated.
If fume emission persists, open doors
and windows to ventilate the room and
let the fire die. Have the chimney
inspected for blockages and clean if
required. Do not relight the fire until the
cause has been found. We recommend
that you seek professional advice.
This appliance has been designed to
be burned with the door closed at all
times other than when refueling.
It should not be operated as an open
fire.
Typical refueling intervals for wood is
1 hour and smokeless fuel is 2 hours.
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Maintenance
Troubleshooting
The chimney should be swept at least
once a year together with the flue pipe
connection. Care should be taken to
ensure that there is not a build up of
soot on the baffle and in the airways of
the appliance.
If the appliance has not been operated
for long periods, the flue should be
inspected and swept before use to
ensure there are no blockages within the
flue.
The grate should be cleaned regularly
and the ashpan emptied daily.
Never allow the ash in the ashpan to
overfill allowing ash to be in contact
with the underside of the grate.
This will overheat the grate and cause
premature wear and distortion.
• The internal vermiculite panels of the
appliance should be checked regularly
for soundness. If any wear and tear is
found, we recommend these parts are
replaced immediately.
• Check the rope door seals are intact
and are not worn. These should be
replaced on an annual basis to ensure
the correct operation of this appliance.
• The glass can be cleaned using a soft
damp cloth or a ceramic glass cleaner
(available from your local stockist)
Use only replacement parts
recommended by the manufacturer.
We recommend that the appliance is serviced annually by a competent
engineer to ensure it’s continued safe operation.
Fire difficult to • Green wood / wet wood Use hardwood logs with a maximum
start / goes out moisture content of 20%
• Logs are too large Use kindling and small logs to start the
fire and once established use split logs
• Not enough primary air Open air control
• Insufficient draft Check the flue is not obstructed
Fire burns too quickly • Too much draft Reduce the air control
• Excessive draft Install a draft stabiliser
Smokes on initial • Flue is cold Burn paper and kindling to increase
lighting heat in flue
Smokes while burning • Insufficient draught Check the flue is not obstructed
Low heat output • Poor quality wood Use seasoned Hardwood (this has a
Higher calorific value)
Problem Probable Cause Action Recommend
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Commissioning Check List
Ensure the serial number has been recorded on the front of this manual for any
future use
Ensure the door seals are in good condition and that the glass is secured correctly
in the door (do not over tighten the glass as this will prohibit its expansion and
could cause the glass to crack)
Ensure that all internal components are fitted correctly (these may have shifted in
transit)
Ensure that the appliance operates correctly during the first firing
Ensure the customer is aware that fumes may be given off during the first firings
as the paint cures
Advise the customer on the safe operation of the appliance
Leave the instruction manuals, operating tool and glove for the customer’s use.
Record the flue draught reading of the appliance
Please tick boxes when each procedure is completed
To remove the internal vermiculite baffle:
Firstly remove the front fuel retaining
bars. Remove the fuel retaining bar
bracket bolts and brackets. Remove the
grate.
Then slightly lift the baffle and ease one
of the side bricks forward by pulling the
front edge of the side brick into the
combustion chamber. Remove the
second side brick in the same manner,
the vermiculite lower baffle can now be
removed by lowering the front edge and
rotating the baffle and removing through
the front door.
Lift the front edge of the upper steel
baffle and drop the back edge of the
steel baffle into the combustion
chamber, remove through door.
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Parts Information
1
3
2
4
5
8
9
34
34
29
30
28 27
35
41
40
10
39
38
20
19 21
22
26
25
14
13
15
18
16
17
23
24
37
11
36
33 32
31
7
12
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1 Door Handle 5612-273 1
2 Door Retaining Bracket 5411-128 1
3 Door Handle Locking Rod 5035-405A 1
4 Locking Rod Grub Screw GRUBSCREW 2
5 Cast Iron Door 4490-1385A 1
6 Door Locking Plate(Not Shown) 5011-406A 1
7 Glass Clip 6612-219 4
8 Glass Gasket 8400-276B 1
9 Door Gasket 8400-276B 2
10 Glass 5540-312 1
11 Airwash Deflector 3811-847 1
12 Left Hand Vermiculite Side Brick 6081-1003A 1
13 Top Hinge Pin Assembly 5135-401 1
14 Lower Vermiculite Baffle 6081-1006 1
15 Upper Steel Baffle 3711-216 1
16 Flue Collar Retaining Nut M8 Tensile Steel Nut 2
17 Flue Collar Retaining Bolt M8 30mm Tensile Steel 2
18 Flue Collar Gasket 8400-276B 1
19 Flue Collar 3490-047 1
20 Rear Vermiculite Brick 6081-1005 1
21 Rear Tertiary Air Chamber 3811-864 1
22 Steel Body Complete 3311-1037 1
23 Rear Air Separation Chamber 3811-844A 1
24 Blanking Plate Gasket 8400-276B 1
25 Blanking Plate 4111-136 1
26 Rear Heat Shield 4811-360A 1
27 Air Intake Collar 3822-576 1
28 Air Intake Collar Retaining Screw M3 10mm Allen Bolt 3
29 Bottom Air Chamber 3811-928 1
30 Air Intake Blanking Plate 3811-551A 1
31 Secondary Air Control Lever 5311-791 1
32 Primary Air Control Lever 5311-790 1
33 Tertiary Air Control Lever 5311-795 1
34 Air Control Lever Linear Spring 6536-018 3
35 Multifuel Grate 5411-127 1
36 Right Vermiculite Side Brick 6081-1004A 1
37 Fuel Retaining Bar 4290-1216A 2
38 Fuel Retaining Bar Bracket 7911-1212 2
39 Ashpan 4911-204 1
40 Leg Stand 4311-1108A 1
41 Primary/Secondary Control Knob 5890-044 2
Diagram No. Part No. Description Quantity Required
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Warranty Information
The specifications within this document are provided for information purposes only and are
under no circumstances binding.
10
YEAR
10
YEAR
WARRANTY
With the aim of constantly
improving our products, all
modifications considered
necessary may be made
without notice.
This manual is correct at time
of printing.
Our appliances are
guaranteed against faults and
hidden defects subject to the
following conditions:
The appliance must have been
installed by a registered
competent installer (e.g.
HETAS) or inspected by local
authority Building Control.
The appliance must be installed
and operated in accordance
with our instruction manual.
The guarantee is for a period of
10 years on the appliance body
from the date of purchase.
The following components are
considered as consumables
and are excluded from the
guarantee:
• Grates
• Rope seals
• Ashpan
• Internal vermiculite panels
• Glass
• Baffle plates
Your statutory rights are not
affected by this warranty.
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Warranty Claim Form
In the unlikely event of a warranty claim, please return the above claim form to:
ACR Heat Products Limited, Unit 1, Weston Works,
Weston Lane, Tyseley, Birmingham, B11 3RP, England.
• Tel: [phone] • Fax: [phone]
• E-mail: [email protected] • www.acrheatproducts.co.uk
Customer Name:
Customer Address:
Postcode
Daytime Tel: Mobile Tel:
Model Name: Model Number:
Serial Number: Date of purchase:
Date of installation:
Installer’s Name and address:
Installer’s Registration Number:
Building Control Certificate Number:
(if not installed by a registered competent installer)
Dealer Name and address:
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ACR Heat Products Limited, Unit 1, Weston Works,
Weston Lane, Tyseley Birmingham B11 3RP, England.
• Tel: [phone] • Fax: [phone]
• E-mail: [email protected] • www.acrheatproducts.co.uk
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