AGA Shawbury User manual

Shawbury Wood Stove
(Smoke Exempt)
INSTALLATION AND OPERATING INSTRUCTIONS
This appliance is hot while in operation and retains its heat for a long period of time after use.
Children, aged or infirm persons should be supervised at all times and should not be allowed
to touch the hot working surfaces while in use or until the appliance has thoroughly cooled.
When using the stove in situations where children, aged and/or infirm persons are
present a fireguard must be used to prevent accidental contact with the stove. The fireguard
should be manufactured in accordance with BS 8423:2002.

TABLE OF CONTENTS
PAGE NO.
1. Installation & Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fire Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Asbestos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. The Clean Air Act 1993 & Smoke Control Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Chimney / Flues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Down Draughts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7. Ventilation & Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8. Commissioning & Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10. Floor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
11. Clearance to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12. Safe Distance from Chimneys & from Flammable materials . . . . . . . . . . . . . . . . . . . . . 5
13. Stove Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
14. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
15. Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16. Recommended Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
17. Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Refuelling onto a low firebed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation with door left open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
18. Dampers / Air Controls Left Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
19. De-Ashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
20. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
21. Chimney Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
22. Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
23. Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
24. Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
25 CO Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
26. Fire Brick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
27. Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Glass Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
28. Summer Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
29. Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1

INSTALLATION & OPERATING INSTRUCTIONS
GENERAL
When installing, operating and maintaining your
stove respect basic standards of fire safety. Read
these instructions carefully before commencing the
installation. Failure to do so may result in damage to
persons or property. Save these instructions for
future reference.
Special care must be taken when installing the stove
such that the requirements of the Health & Safety at
Work Act are met.
Any alteration that is not approved by AGA, could
invalidate the approval of the appliance, operation of
the warranty and could also affect your statutory
rights. Use only authorised replacement parts.
Handling
Adequate facilities must be available for loading,
unloading and site handling.
Fire Cement
Some types of fire cement are caustic and should
not be allowed to come into contact with the skin. In
case of contact with the skin wash immediately with
plenty of water.
Asbestos
This stove contains no asbestos. If there is a possi-
bility of disturbing any asbestos in the course of
installation then please seek guidance and use
appropriate protective equipment.
Metal Parts
When installing or servicing this stove care should
be taken to avoid the possibility of personal injury.
THE CLEAN AIR ACT 1993 AND SMOKE
CONTROL AREAS
The Clean Air Act 1993 and Smoke Control Areas”
Under the Clean Air Act local authorities may
declare the whole or part of the district of the author-
ity 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
2
NOTE: Please note that it is a legal requirement
under England & Wales Building Regulations that
the installation of the stove is either carried out
under Local Authority Building Control approval or
is installed by a Competent Person registered with
a Government approved Competent Persons
Scheme. HETAS Ltd operate such a Scheme and
a listing of their Registered Competent Persons
can be found on their website at www.hetas.co.uk.
The installation must be completed in
accordance with current National and
European Standards and Local Codes. It
should be noted that the requirements and
these publications may be superseded during
the life of this manual.
IMPORTANT WARNING: This stove must not be
installed into a chimney that serves any other
heating appliance. There must not be an extrac-
tor fan fitted in the same room as the stove as
this can cause the stove to emit fumes into the
room.
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.
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 require-
ments”
The Shawbury stove has been recommeded for use
in smoke controlled areas when burning wood logs
only and fitted with a factory modified air control to
allow a minimum amount of combustion air when the
air controls are set at minimum.

PRE-INSTALLATION
Before using the stove for the first time all remaining
stickers must be removed, all accessories must be
removed from the ashpan, check if any items have
become dislodged during transport.
CHIMNEY/FLUES
The stove is a radiant room heater and must be con-
nected to a proper type chimney/flue for safe evac-
uation of products of combustion. The chimney/flue
must have a diameter of 150mm or equivalent cross
sectional area. Never connect to a smaller size
chimney/flue. Do not connect to a chimney/flue
serving another appliance. A minimum chimney/flue
height of 4.5 metres from the flue spigot on the stove
to the top of the chimney/flue is required. The chim-
ney/flue must be constructed of material capable of
withstanding a soot fire in the chimney/flue which
can lead to temperatures of 1000 degrees. The
chimney/flue must be constructed with sockets
uppermost so that when condensation occurs within
the pipe, it should flow down the inside of the pipe
that it will transfer to the inner of the next pipe with-
out seeping through the joints. The chimney/flue
should provide a minimum continuous draught of 12
pascals, if the stove is connected into an existing
chimney where the refractory flue liner is of a diam-
eter in excess of 200mm the chimney should be
relined using a flexible flue liner. The flexi liner is not
recommended to be connected directly to the appli-
ance, there should be a minimum of 0.6 meters rigid
flue pipe coming off the appliance. The chimney/flue
should be designed to allow for cleaning of the
stove, use pipes with cleaning doors where neces-
sary.
Avoid the use of 90 degree elbows, use 2 x 45o
bends instead. Horizontal runs of flue pipe should
be avoided, where it is unavoidable the maximum
permitted horizontal run is 150mm. The
chimney/flue must have the necessary clearance
distance from combustible material. The chimney
termination must be free of any obstructions, see
requirements under Approved Document J, avail-
able to download at www.planningportal.gov.uk
For guidance when installing new chimney systems
or relining existing chimneys please refer to BS EN
15287:
DOWN DRAUGHTS
However well designed constructed and positioned,
the satisfactory performance of the flue can be
adversely affected by down draught caused by near-
by hills, adjacent tall buildings or trees. These can
deflect wind to blow directly down the flue or create
3
a zone of low pressure over the terminal. A suitable
anti-down draught terminal or cowl will usually effec-
tively combat direct down blow but no cowl is likely
to prevent down draught due to a low pressure zone.
(See Fig.1)
Direction of wind
Direction of wind
Direction of wind
Pressure zone
Pressure zone
Suction zone
Suction zone
Pressure zone Suction zone
Fig 1
VENTILATION AND COMBUSTION AIR
REQUIREMENTS
Refer to extract from Building Regulations Part J to
determine size of permanent air vent.
Install where draft stabilizer is fitted:
Permanently open vents as below:
If design air permeability >5.0m3/(h.m2) then
300mm2/kW for first 5kW of appliance rated output
850mm2/kW for balance of appliance rated output
If design air permeability <5.0m3/(h.m2) then
850mm2/kW of appliance rated output (4)
Install where no draft stabilizer is fitted:
Permanently open vents as below:
If design air permeability >5.0m3/(h.m2) then
550mm2/kW of appliance rated output above 5kW
If design air permaeability <5.0m3/(h.m2) then
550mm2per kW of appliance rated output (4)

4
If there is another appliance using air fitted in the
same or adjacent room, it will be necessary to pro-
vide an additional air supply.
All materials used in the manufacture of air vents
should be such that the vent is dimensionally stable,
corrosion resistant, and no provision for closure. Air
inlet grills should be positioned so they do not
become liable to blockage. The effective free area
of any vent should be ascertained before installa-
tion. The effect of any grills should be allowed for
when determining the effective free area of any vent.
Air vents direct to the outside of the building should
be located so that any air current produced will not
pass through normally occupied areas of the room.
An air vent outside the building should not be locat-
ed less than the dimensions specified within the
Building Regulations and B.S. 8303: Part 1 from any
part of any flue terminal. These air vents must also
be satisfactorily fire proofed as per Building
Regulations and B.S. 8303: Part 1.
Air vents in internal walls should not communicate
with bedrooms, bedsits, toilets, bathrooms or rooms
containing a shower.
Air vents traversing cavity walls should include a
continuous duct across the cavity. The duct should
be installed in such a manner as not to impair the
weather resistance of the cavity.
Joints between air vents and outside walls should be
sealed to prevent the ingress of moisture. Existing
air vents should be of the correct size and unob-
structed for the appliance in use. If there is an
extraction fan fitted in adjacent rooms where this
appliance is fitted, additional air vents may be
required to alleviate the possibility of spillage of
products of combustion from the appliance/flue
while the fan is in operation. Refer to B.S. 8303 Part
1.
Where such an installation exists, a test for spillage
should be made with the fan or fans and other
appliances using air in operation at full rate, (i.e.
extraction fans, tumble dryers) with all external
doors and windows closed.
If spillage occurs following the above operation, an
additional air vent of sufficient size to prevent this
occurrence should be installed.
Note:- If there is any work that is being carried out
that would effect the air quality supplied to the stove
such as sanding a floor or glueing linoleum etc. the
stove must be out of operation. The dust or vapours
may be a potential hazard, the air supply and local
area needs to be thoroughly ventilated before
putting the stove in operation again.
COMMISSIONING & HANDOVER
On completion of the installation allow a suitable
period of time for any fire cement and mortar to dry
out, when a small fire may be lit and checked to
ensure the smoke and fumes are taken from the
stove up the chimney and emitted safely to the
atmosphere. Do not run at full output for at least
24 hours.
On completion of the installation and commissioning
ensure that the operating instructions for the stove
are left with the customer. Ensure to advise the cus-
tomer on the correct use of the appliance with the
fuels likely to be used on the stove and warn them to
use only the recommended fuels for the stove.
Advise the user what to do should smoke or fumes
be emitted from the stove. The customer should be
warned to use a fire guard to BS 8423:2002 in the
presence of children, aged and/or infirm persons.
LOCATION
There are several conditions to be considered in
selecting a location for your stove.
A. Allowances for proper clearances to
combustibles of the stove and flue pipes.
B. The product must be installed on a non
combustible hearth with adequate load bearing
capacity.
C. Fluing considerations; length of flue, length of
horizontal run, flue termination.
D. Location within area to be heated.
FLOOR PROTECTION
It is recommended that this appliance is installed on
a solid, level, concrete base, a non combustible
hearth conforming to current Building Regulations
must extend to the front of the appliance.