Aga-Rayburn Coalbrookdale Little Wenlock Gas Power Flue User guide

WARNING
This information is a copy of an original
archive, therefore Aga cannot be held
responsible for its continued accuracy.

Consumer Protection
As manufacturers and suppliers of cooking and heating products.We
take every care to ensure, as far as is reasonably practical, that these
products are so designed and constructed as to meet the general
safety requirement when properly used and installed. To this end,
our products are thoroughly tested and examined before despatch.
IMPORTANT NOTICE: Any alteration that is not approved by Aga-
Rayburn could invalidate the approval of the appliance, operation of
the warranty and could affect your statutory rights.
Important
This appliance may contain some of the materials that are indicated
It is the Users/Installers responsibility to ensure that the necessary
personal protective clothing is worn when handling where
applicable, the pertinent parts that contain any of the listed materials
that could be interpreted as being injurious to health and safety, see
below for information.
Firebricks, Fuel beds, Artificial Fuels - when handling use
disposable gloves.
Fire cement - when handling use disposable gloves.
Glues and Sealants - exercise caution - if these are still in liquid form
use face mask and disposable gloves.
Glass Yarn, Mineral Wool, Insulation Pads, Ceramic Fibre,
Kerosene/Gas Oil - may be harmful if inhaled. May be irritating to
skin, eyes, nose and throat. When handling avoid contact with skin
or eyes. Use disposable gloves, face-masks and eye protection.
After handling wash hands and other exposed parts. When
disposing of the product, reduce dust with water spray, ensure that
parts are securely wrapped.
10/00 EINS 511110
Installation
and
Servicing
Instructions
For use in GB and IE
Natural Gas Cat I2H (G20) at a supply pressure of 20mbar
Propane Gas Cat I3P (G31) at a supply pressure of 37mbar
Little Wenlock Gas Power Flue (GS1iPF)
Little Wenlock Gas Power Flue Traditional - (GS1iPF -Traditional)
THIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE WITH THE RULES IN FORCE
DESN 511292
STANDARD DOOR OPTION ILLUSTRATED

2
MAX. HEAT INPUT (GROSS)
MAX. HEAT OUTPUT (GROSS)
MIN. HEAT INPUT (GROSS)
MIN. HEAT OUTPUT (GROSS)
MAX. SETTING PRESSURE (COLD)
BURNER INJECTOR
PILOT INJECTOR
SPARK GAP
IGNITION
6.00 kW 5.5kW
NAT. GAS PROPANE
3.96 kW
3.30 kW
2.20 kW
35.5 mbar
PROPANE - Cat 92 - 180
LPG - 9206
2 - 3 mm
PIEZO SPARK GENERATOR
4.62 kW
3.30 kW
2.31 kW
18 mbar
NAT - Cat 82 - 360
NAT - NG 9008
2 - 3 mm
PIEZO SPARK GENERATOR
APPLIANCE WEIGHT 68.5kg68.5 kg
FLUE 50mm Ø50mm Ø
ELECTRICAL REQUIREMENTS 230 VOLTS A/C 50Hz 30W
A 3 amp FUSE TO BE FITTED
SPECIFICATIONS
COALBROOKDALE GS1iPF
DESN 511293

The Little Wenlock Gas Power Flue (GS1iPF) is factory set
to operate on natural gas or propane (See data label) and
is available with a standard or traditional door option.
Due to newness the stove may give off a slight smell for
a short period after commissioning. This is quite normal
and will disappear after a few hours operation, open
windows and doors if required.
The Little Wenlock Gas Power Flue (GS1iPF) has one
access door as part of its design. The glass fronted door
is for access to the coals and apart from initial
commissioning of the stove, or in case the pilot is
required to be lit with a taper due to malfunction of the
spark ignition system.
UNDER NO CIRCUMSTANCES MUST THE STOVE BE
OPERATED WITH THIS DOOR OPEN OR IF THE GLASS
IS CRACKED OR BROKEN.
The Little Wenlock Gas Power Flue (GS1iPF) has been
designed similar to a solid fuel stove to relevant safety
standards, but during use, many parts of the appliance
can become HOT to touch. We recommend that you
provide and secure a fireguard complying with BS 6539
when the room is used by elderly, infirm or young
persons.
Note: Illustrations show the appliance fitted with the
standard door option.
The installation of the appliance must be in accordance
with the relevant requirements of the Gas Safety
(Installation and Use) Regulations 1995, Building
Regulations and the Building Standards (Scotland)
(Consolidation) Regulations. It should be in accordance
also with any relevant requirements of the local Gas
Region and Local Authority and the relevant
recommendations of the following current British Codes
of Practice & Standards.
BS.6891: Installation of pipes and meters. Low pressure
installation pipes.
BS.5440: Part 1 Flues & Part 2 Air Supply.
BS.5871: Part 1 Installation of Gas Fires, Convector
Heaters, Fire/Back Boilers.
BS.6461: Codes of Practice for factory-made insulated
chimneys for internal application.
BS.8303: Solid fuel appliance flue system.
In your own interests and that of safety to comply with
the law all gas appliances should be installed by
competent persons, (Corgi Registered) in accordance
with the above regulations and with these instructions .
Failure to install the appliance correctly could lead to
prosecution.
NOTE! This stove is fitted with a spillage safety device. In
the event of the flue becoming blocked the fan will
increase to its high speed (indicated by the red light on
the control box) if this fails to clear the blockage the
appliance will shut down.
WARNING: UNDER NO CIRCUMSTANCES IS THE
SPILLAGE MONITORING DEVICE TO BE TAMPERED
WITH. IF PROBLEMS PERSIST SEEK EXPERT ADVICE.
WHEN THE SPILLAGE MONITORING SYSTEM OR ANY
OF ITS PARTS ARE EXCHANGED, ONLY ORIGINAL
PARTS SHALL BE USED.
INTRODUCTION INSTALLATION INSTRUCTIONS
3

WARNING: THIS APPLIANCE MUST BE EARTHED.
The appliance is suitable for use on 230V 50Hz mains
supply only.
The wires in the mains lead on this appliance are coloured
in accordance with the following:
Green and Yellow Earth
Blue Neutral
Brown Live
As the colours of the wiring in the mains lead of this
appliance may not correspond with the marking on the
plug terminal, they should be connected as shown in Fig.
1.
ENSURE ELECTRIC MAINS LEAD IS KEPT CLEAR OF
ANY HOT SURFACE
IF THE SUPPLY CORD IS DAMAGED IT MUST BE
REPLACED BY A SPECIAL CORD OR ASSEMBLY
AVAILABLE FROM THE MANUFACTURER OR ITS
SERVICE AGENT.
This appliance must be protected by a 3A fuse, if a 13A
plug is used or, if any other type of plug is used, by a 5A
fuse either in the plug or adaptor or at the distribution
board in order to protect the appliance.
4
ELECTRICAL CONNECTION
CIRCUIT DIAGRAM
FIG. 1 DESN 511294
DESN 511319

The appliance must be installed on a base of
incombustible material, at least 12mm thick, extending to
at least the front of the stove supporting legs and to
85mm beyond each side of the stove (570mm). See Fig.
2. No clearance is required in front of the hearth
The stove must be installed with a hearth capable of
withstanding a maximum temperature of 150˚C.
Conglomerate marble, marble and tiled surrounds can
meet this requirement.
The stove must be installed with a non-combustible wall
at the rear. In the event of a combustible wall being
present a shield of non-combustible material, at least
25mm thick and to the dimensions in Fig. 2 should be
fitted.
Clearances for Shelves: A wooden shelf may be fitted
above the stove. The underside of the combustible shelf
above the top of the stove should be dimensioned
accordingly.
Depth of shelf Height to underside of shelf Y
150mm 558mm
175mm 575mm
200mm 600mm
225mm 650mm
250mm 700mm
275mm 750mm
300mm 800mm
NOTE:
THE PROPANE VERSION MUST NEVER BE INSTALLED
IN A ROOM OR EXTERNAL SPACE BELOW GROUND
LEVEL E.G. IN A BASEMENT OR CELLAR.
IT IS IMPERATIVE THAT THE STOVE WHEN INSTALLED
IS LEVEL IN ALL DIRECTIONS.
5
THE LOCATION
FIG. 2
DESN 511295
DESN 511296

The flue pipe must terminate on an outside wall
observing the minimum clearances in Fig. 3.
Position Minimum Spacing
mm
ADirectly below an openable window,
air vent, or an other ventilation opening 300
BBelow gutter, drain/soil pipe 75
CBelow eaves 200
DBelow a balcony or car port roof 200
EFrom vertical drain pipes and soil pipes 75
FFrom internal to external corners 150
GAbove adjacent ground, roof or balcony eaves 150
HFrom surface facing the terminal 600
IFacing terminals 1200
JFrom opening (door/window)
in car port into dwelling 1200
KVertical from a terminal 1500
LHorizontally from a terminal 300
6
THE FLUE
FIG.3 DESN511053
DESN511052

The appliances fluing can exist in a number of different
ways depending upon the position of an outside wall and
where the flue outlet is to be positioned.
ARear flue outlet directly behind appliance
- supplied as standard Fig. 5.
BRear flue outlet with flue running behind wall
- optional Fig. 6.
COutlet with flue running in room (MAXIMUM
OF 1 ADDITIONAL BEND) - optional.
UNDER NO CIRCUMSTANCES MUST ADDITIONAL
BENDS OR FLUE PIPE LENGTHS OF OVER 2M BE
USED. THE APPLIANCE CAN ONLY BE INSTALLED
USING THE FLUE PIPE MATERIAL SUPPLIED.
NO FORM OF RESTRICTION CAN BE FITTED TO THE
FLUE SYSTEM.
FLUE TERMINAL
A terminal guard must be fitted irrespective of height of
the installation above ground level Fig. 4.
FLUE LENGTH
THE LENGTH OF THE FLUE, MEASURED FROM THE
CENTRE LINE OF THE FLUE OUTLET TO THE OUTER
FACE OF THE OUTSIDE WALL MUST BE BETWEEN
200MM MINIMUM AND 2M MAXIMUM AND USE NO
MORE THAN 2 BENDS.
7
THE FLUE
FIG. 5
FIG. 6
DESN 511297
DESN 511298
FIG. 4 DESN. 511189

DIRECT VENT INSTALLATION
1. Flue drilling point. Position of the hole through the wall
should be as Fig. 7.
2. Assemble the flue elbow flue connector and flue as
shown in Fig. 8 ensuring that the seals are in position.
3. Cut flue pipe to length ensuring that it protrudes
through the wall a minimum of 10mm.
4. Seal around hole with cement and fit cover plate and
terminal guard.
8
THE FLUE
FIG. 7
FIG. 8
DESN 511300
DESN 511301

ALONG AN INSIDE/OUTSIDE WALL
1. Mark position of the top of the hearth on the inside
face of the exterior wall and also the flue hole position
(Fig. 9).
Note: Check that the flue length will be between
200mm and 2M.
2. Drill the hole for the flue pipe, the centre being 41mm
above the top of the hearth and 45mm from the
corner.
3. The flue pipe and elbows can be assembled as
described previously, see Fig. 8.
PLEASE NOTE THAT THE FLUE PIPE IS HOT, IF THE
FLUE IS RUNNING ALONG THE INSIDE WALL THE
FITTING OF A NON COMBUSTIBLE FLUE COVER IS
STRONGLY RECOMMENDED.
9
THE FLUE
FIG. 9 DESN 511302

Flue clamping brackets should be fitted (see Fig. 10)
ensuring the spacing between brackets is sufficient to
provide sturdy support for the flue pipe.
Note: When installing the flue along an inside wall all
combustible material i.e. skirting board, wallpaper must
be removed from the immediate vicinity of the flue pipe.
10
FLUE CLAMPING BRACKETS
FIG. 10 DESN 511303

The stove does not normally require any additional
purpose made ventilation. However, we recommend that
the room has a permanent vent of minimum free air area
of 36cm2.
If there is any type of extractor fan fitted in the same
room as the stove, there is a possibility that if adequate
air inlet area from outside is not provided, spillage of the
products from the appliance flue could occur when the
extractor fan is in operation. Where such installations
occur, a spillage test as detailed in BS.5440 Part 1 must
be carried out.
The complete installation must be tested for soundness
and purged as described in BS.6891.
The gas inlet to the stove is 8mm dia compression, and
providing the distance from the service cock to the stove
does not exceed 1.5m, 8mm dia rigid or semi-rigid supply
pipe may be used.
Above this length, 15mm dia rigid or semi-rigid pipe
should be used.
A service cock must be fitted adjacent to this appliance.
Unpacking
Remove all parts from inside the pack and ensure that no
damage has occurred during delivery transit. If so, please
contact your local stockist.
Items in Pack:
Instructions-Installation-Servicing-Operating
Coal Guard
Small Coals (12)
Large Coals (8)
Finger Coals (4)
Control Cover
Door Locking Tool
Clay Aggregate
Flue Pipe (1 metre length)
90˚Flue Bend (1)
Flue Connector (2)
Terminal Guard (2)
Wall Plate
Position the appliance in accordance with the instructions
given in the section ‘LOCATION’ and connect the flue
pipe in accordance with the section ‘THE FLUE’.
FLEXIBLE PIPE/CONNECTIONS MUST NOT BE USED.
Connect the stove to the gas supply. (See Gas
Connection).
11
AIR SUPPLY
EFFECT OF EXTRACTION FAN
GAS CONNECTION
APPLIANCE ASSEMBLY
INSTALLING THE APPLIANCE

Open the door of the stove (Using the tools supplied), see
Fig. 11) as follows:
1. Loosen the locking screw with the hex. driver.
2. Turn the door catch with the tool as illustrated.
Pour the aggregate into the burner tray as illustrated in
Fig. 12.
Fit the coal guard as illustrated in Fig. 12.
Do not compress or tap down. Any excess should be
kept and handed to the user for future use.
Positioning the Coals
Carefully place the coals on the coal bed as illustrated in
Figs. 13, 14 , 15 and 16.
Close the door and lock (Using the tools supplied).
WARNING: USE ONLY THE SIMULATED COALS
SUPPLIED WITH THE APPLIANCE TO BUILD THE BED.
UNDER NO CIRCUMSTANCES USE EXTRA COALS
OR PUT ANY OTHER MATERIALS ON THE FUEL BED.
DO NOT OPERATE THE STOVE WITH THE DOOR
OPEN OR IF THE GLASS IS CRACKED OR BROKEN.
THE DOOR CATCH IS HOT AND SHOULD ONLY BE
OPENED WITH THE TOOLS PROVIDED.
Hands should be washed after handling coals. (If gloves
are not used).
12
LAYING THE FUEL BED
FIG. 11 DESN 511305 A

13
LAYING THE FUEL BED
FIG. 12
FIG. 13
FIG. 14
POUR THE CLAY AGGREGATE
SUPPLIED INTO THE TRAY
UNTIL IT IS FLUSH WITH THE
TOP OF THE BURNER TRAY.
LOCATE COAL GUARD.
LOCATE 12 SMALL COALS
AS SHOWN.
PLACE 4 LARGE COALS
AS SHOWN.

14
FIG. 15
FIG. 16
PLACE THE REMAINING 4
LARGE COALS AS SHOWN.
PLACE THE 4 FINGER COALS
ON TOP OF THE LARGE
COALS AS SHOWN.

NO SMOKING OR NAKED LIGHTS
The whole installation must be inspected and tested for
soundness and purged up to the gas service cock in
accordance with BS. 6891.
Remove the pressure test point sealing screw on the
burner feed pipe, located at the left hand side of the
control valve, connect a suitable pressure gauge. (See
Fig. 17).
The control tap is marked with the following positions:-
OFF
PILOT ONLY
MINIMUM
MAXIMUM
The stove is fitted with a piezo spark ignitor.
Note: If the main burner or pilot are extinguished for
any reason do not attempt to re-light the pilot for
three minutes.
Ensure the electricity supply is connected and turned on
press the on button located on the fan control box (see
Fig. 18) this will illuminate the light and the fan should
operate at high speed for approx. 15-20 seconds the light
will go off, the fan speed will reduce and the appliance
can be lit.
15
●
COMMISSIONING AND TESTING
TO OPERATE THE FAN
FIG. 17 DESN 511311
FIG. 18 DESN 511312

Ensure that the control knob is in the OFF (●) position
(Fig. 19).
Fully depress the control knob and turn anti-clockwise
(keeping the control valve fully depressed) until the pilot
position ( ) is reached (Fig. 20). If the pilot has not lit
repeat the operation.
Once the pilot is lit continue to hold in the control knob for
a further 10-15 seconds to establish the pilot. When the
control knob is released the pilot should remain alight. If
the pilot fails to remain alight refer to fault finding section
of this document.
If required the pilot may be lit by a long spill or taper as
follows:
Open the door of the stove (using the tools supplied) (See
Fig. 11).
Apply a lighted long spill or taper to the pilot (See Fig. 21)
positioned at the front LH side of the burner tray.
Fully depress the control knob and turn anti-clockwise
(keeping the control knob fully depressed) until the spark
position ( ) has been removed and the pilot should light.
Once the pilot is lit remove the long spill or taper,
continue to hold the control knob for 10 to 15 seconds to
establish the pilot. When the knob is released, the pilot
should remain alight. If the pilot fails to remain alight,
repeat the procedure, but hold the knob in longer.
When pilot is established close and lock the door
(using the tools supplied).
If the pilot is not alight, follow procedure to light pilot.
Turn the control knob anti-clockwise to the full on position
( ) (Fig. 22). The main burner will light. At this setting the
pressure should be 17.7 +/-1.0mbar with an inlet
pressure of 20mbar for natural gas, or 36 +/-1.0mbar with
an inlet pressure of 37mbar for propane.
Depress and turn the control knob clockwise to the pilot
position ( ) (Fig. 23). The stove will go out and the pilot
will remain alight. Remove the pressure gauge and
replace the test point sealing screw.
Turn stove to maximum setting ( ) (Fig. 24) and check
for gas soundness.
16
TO LIGHT THE PILOT
TO LIGHT STOVE
FIG 19.
FIG 20.
FIG 22.
FIG 23.
FIG 24.
FIG. 21. DESN 511313

Turn the gas control knob to the minimum gas rate
position ( ) (Fig. 25), slightly depress the knob and
continue turning to the pilot position ( ) (Fig. 26). The fire
will go out and the pilot will remain lit and may be left on
permanently.
Turn off fan.
Turn the stove off as described. Depress the control
knob, turn to the off position (●) (Fig. 27) and the pilot will
go out.
Ensure fan is switched off.
Should the stove be subject to a power cut. On
restoration of the power the gas control will require
resetting manually (see page 15).
17
TO TURN STOVE OFF
TO TURN STOVE AND PILOT OFF
FIG 25.
FIG 26.
FIG 27.
POWER FAILURE

Ensure that all doors and windows of the room are
closed.
Light the stove as described. Leave on maximum rate for
5 minutes.
If there is a fan in a nearby room then the spillage test
must be repeated with the fan turned on and any
interconnecting doors between the stove and the fan
location left open.
A spillage test as detailed in BS. 5440 must be carried out
after 5 minutes as follows:- By holding a smoke match so
that match head is approximately 3mm up inside the
lower edge of the draught diverter (See Fig. 28). Spillage
is indicated by smoke being displaced outwards from the
draught diverter. If in doubt repeat after a further 10
minutes.
If spillage is detected the fan may be faulty. The fault
must be corrected before leaving the stove installed.
if the fault cannot be corrected turn off and disconnect
the gas supply to the stove and seek expert advice.
Hand over all the instructions to the user and explain how
to light and operate the appliance.
Impress upon the user that the coals must be located in
accordance with the instructions and that the appliance
MUST NOT be operated with the stove door open or if
the glass is cracked or broken. The appliance should be
serviced at regular intervals by a competent person to
ensure safe operation.
Point out the removable warning label which the
customer must remove and read.
Advise the user that any smell emitted from the stove on
initial lighting will quickly clear away with use.
The door tools must be stored in a safe place out of the
reach of children.
18
CHECK FOR CLEARANCE OF
PRODUCTS OF COMBUSTION INSTRUCT USER
FIG. 28 DESN 511314

19
SERVICING AND REPLACEMENT PARTS
FIG. 29 DESN 511315