Bodart & Gonay Series 603 User manual

IN-FIRE
Series 603 - 683 - 743
604 - 684 - 744
USER'S MANUAL,
MAINTENANCE MANUAL
INSTALLATION INSTRUCTIONS
04/98
07DH683A

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Dear Customer
Congratulations on the purchase of your new Bodart & Gonay appliance!
Your choice shows the interest you have for high quality products. You are now a full member
of the large international family of Bodart & Gonay customers, who have enjoyed for many years
the elegance, efficiency and reliability of our equipment.
This is why we deem it important to provide you with this user's and maintenance manual: to
allow you to use your equipment under the best possible conditions and in the most optimal
manner, and furthermore to increase its operating life. We strongly advise you to read it
carefully.
And, of course, to store it in a place where you are sure to find it again without any problem.
We also provide hereunder a space where you can note for yourself the date of purchase,
reference and the name and address of your supplier, so that this information is always kept
safely.
Also keep carefully the invoice or proof of purchase (necessary for the guarantee) and we advise
you to clip them together with this manual.
We wish you every satisfaction with your Bodart & Gonay equipment.
After sales service.
*Type of equipment: ................................................................................................................
*Reference: ..............................................................................................................................
*Date of purchase: ....../....../20......
*Dealer: - name: ....................................................................................................................
- street: ........................................................................................................................
- city: ........................................................................................................................
- phone: .....................................................................................................................
In order to put back the baffles in the position adapted to your chimney stack after a
chimney sweeping, note here the ideal position (cf. page 21, adjustment of the baffles):
-Upper baffle: open - ½ open - closed
-Lower baffle: open - closed

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TABLE OF CONTENTS
USERS AND MAINTENANCE MANUAL
A. IMPORTANT RECOMMENDATIONS 4
BOPERATION OF THE APPLIANCE 5
C. MAINTENANCE 10
D. OPERATION ANOMALIES 12
E. GUARANTEE 13
INSTALLATION INSTRUCTIONS
A. SAFETY 15
B. RECESS 16
C. CHIMNEY 16
D. HOT AIR DUCT 18
E. ELECTRICAL INSTALLATION 18
F. ADJUSTMENT OF THE BAFFLES 21
G. DISMANTLING THE BAFFLES:22
H. INSTALLATION OF THE APPLIANCE 23

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USERS AND MAINTENANCE MANUAL
A. IMPORTANT RECOMMENDATIONS
-Pull to open the door flap.
-Carry out the installation and follow the safety rules
(cf. installation instructions).
-It is imperative to place the parker screw in the middle of the above cross bar of
the frame, in order to attach the frame to the body of the appliance.
-FIRST FIRE:
*Set the fans to maximum speed to run them in (during about 12
hours).
*The first fire bakes the paint which leads to an emission of smoke
(ýVENTILATE THE ROOM)
DO NOT TOUCH THE PAINT UNTIL THE APPLIANCE HAS COOLED,
BECAUSE IT GETS SOFT AT THE FIRST FIRING.
-IT IS MANDATORY AT EACH FIRE:
* TO SHUT THE DOOR OF THE ASH BOX
* TO CLOSE THE DOOR FLAP
* OPERATE THE CONVECTIONS FANS (except when running at the minimum rate)

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B. OPERATION OF THE APPLIANCE
I. USE OF THE CONTROL AND SAFETY DEVICES
1) The door flap:NEVER KEEP IT OPEN DURING THE OPERATION OF THE
APPLIANCE. ALWAYS CLOSE IT BEFORE OPENING THE
DOOR.
NEVER OPEN IT WHEN THE DOOR IS OPEN.
2) The thermostat:It adjusts the quantity of primary air for burning in function of its
position. Its flap opens and closes according to the temperature
of the convection chamber. Its control button is telescopic to
make its operation easier.
3) The secondary air dosing device:It allows to increase (lever to the left) or to
decrease (lever to the right) the secondary air
flow which also removes the smoke from the
glass window.
4) The door of the ash box: It provides access to the ash box and to the de-ashing
arm. IT MUST ALWAYS BE TIGHTLY CLOSED
WHEN THE FIRE IS ON (otherwise the combustion air
is not controlled and the fire races.
ýOVERHEATING OF THE APPLIANCE).

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5) De-ashing arm:To use it, pull it towards the front. It is used to adapt the grate to
the type of fuel to be burnt (left position: open grate for coal;
right position: closed grate for wood). Removing the ashes is
made by moving it from the right to the left.
6) The ashpan:In the shape of a shovel to allow the collection of ashes at the back
of the equipment. Monitor the filling of the ashpan and empty it
before it overflows.
7) Closing the door and the "cold handle":With the DOOR FLAP CLOSED place
the cold handle in the hole of the latch
to open and close.
8) Closing lever:USE THIS LEVER TO CLOSE THE DOOR FLAP.
9) Microswitch:A switch which automatically stops the fan convection when the
door is opened.
10) The convection air filters:They prevent dirt accumulation on the fans and the
circulation of dust. They may be removed without
tools for cleaning.
The variator:It allows you to control the speed of the fans.
1. Adjustment of the speed.
2. 2A fuse (remove the button, unscrew the plate and pull for
replacement)
3. Adjustment screw for the minimum speed - under the button
(calibrated in the factory)

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2OPENING AND CLOSING THE DOOR
WHEN A FIRE IS ON, OPEN THE DOOR SLOWLY. A fast opening may lead to a
temporary spillage of smoke.
TO SHUT THE DOOR, lift the handle, press the door against the combustion chamber
in order to crush the seal slightly, then lower the handle to its stop position.
3OPERATING WITH DIFFERENT FUELS:
1) Wood
The QUALITY of the wood is ESSENTIAL for an optimal operation of the
appliance (efficiency, cleanliness of the window, ...). A quality wood is a dry
wood having dried at least 2 years under a ventilated shelter. To use your
appliance with WOOD, you must place the GRATE in the CLOSED POSITION.
Closed position
Model IF 600 IF 680 IF 740
Maximum load 5 kg 7 kg 9 kg
Recommended load for 1 hour at 2.5 kg 3 kg 3.5 kg
max. rate
REMARK: The use of briquettes is similar to operation th wood.
LIGHTING THE FIRE:

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1. OPEN fully the air flow: THERMOSTAT on 9. Place the grate in the open
position (lever to the left).
2. Place crumpled paper (or fire lighters) and KINDLING FIREWOOD in the
appliance on the grate.
3. LIGHT the FIRE.
4. Leave the door SLIGHTLY AJAR to avoid an accumulation of dirt on the
window,itstemperatureistoo low itcould leads tocondensation and adeposit of
particles on the glaas if the door is closed to early .
5. As soon as the window is sufficiently HOT, CLOSE THE DOOR.
6. Wait until the kindling firewood burns briskly and LOAD the first logs,
choosing the smaller ones to start with.
7. START the VENTILATION (variator "ON").
8. When the fire is hot, CLOSE THE GRATE (lever to the right), adjust the
thermostat to the position wanted.
9. ADJUST THE SPEED OF THE VENTILATION in function of the quantity
of hot air that you need.
LONG DURATION COMBUSTION:
-Keep a bed of glowing embers of 3 to 5 cm on the bottom of the appliance.
-Choose logs of very high cross section.
-Position the thermostat in accordance with the draught of your chimney. A reduced
rate is generally obtained from 0 to 3 enabling your fire to be kept in for longer
periods overnight burning.
REMARK: -The use at a reduced rate for a long time may, because of
condensation, lead to an accumulation of creosote in the
chimney and thus to a risk of setting the chimney on fire.
-AVOID A OPERATING AT A REDUCED RATE WHEN THE
ATMOSPHERICCONDITIONSAREUNFAVOURABLE(low
pressure and high humidity) as this could cause problems .

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2) Coal
Use anthracite or non bituminous coal, with a size of 20/30 (or 12/22 if the
draught is sufficient). To use your appliance with COAL, place the GRATE in
the OPEN POSITION.
Open position
REMARK: For people frequently using coal, a basket of heat resisting
steel is available as an accessory. It allows a better
combustion of the coal and a protection of the air
distributor at very high combustion temperature.
LIGHTING A COAL FIRE:
Points 1 to 5 as for wood fuel.
6. START the VENTILATION.
7. Place two coal shovels full of coal, WITHOUT SPREADING IT on the
top of the briskly burning fire.
8. As soon as the fire burns through, place a LOAD of about 2.5 to 4 kg
(depending on the model).
9. When the fire has burnt through the mass (flames will appear), add a
SECOND LOAD.
10. Let the fire increase before reducing GRADUALLY the air admission
until the position corresponding to the heat requirement is reached.
11. ALSO ADJUST THE SPEED OF THE VENTILATION.

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REMARK: do not use the equipment with coal in warm weather. The
draught and the burn rate being reduced, the combustion
risks to becoming incomplete.
3) Prohibited fuels
The use of treated wood (painted, ... etc.) and any other salvaged material that
can emit noxious gazes for the environment and aggressive towards the
components of the appliance is NOT ALLOWED and eliminates the rights of
guarantee. For the same reasons, PETROLEUM COKE must not be used. The
use of LIQUID FUELS (petrol, ...) is FORBIDDEN (even to light the fire).
4THE USE OF THE SECONDARY AIR DOSER
TheBodart & Gonay appliances have been designed to provide the best possible
combustion. The least polluting combustion for the environment is obtained by
closing as much as possible the air doser (positioned to the right). However,
depending on the draught and the fuel, this position may lead to a faster dirtying of
the window. In this case open gradually the air doser towards the left until a
satisfactory situation is obtained.
5OPERATION OF THE THERMOCONTACT (OPTION)
This thermocontact is a switch that automatically switches the ventilation on when the
equipment is hot and stops it when it has cooled. At the time of LIGHTING, there is
a DELAY of about 20 minutes before it switches on, this is NORMAL.
C. MAINTENANCE
CHIMNEY SWEEPING: Not only to comply with the LAW, but from the point of view
of SAFETY, have the chimney swept at least once per year.
SDismantle the 2 baffles (cf. "Dismantling the baffles"). Close the door, thermostat,
secondary air doser and the ash box door.
SPlace the grate in the closed position (wood).
SAfter the dust has settled, it can be removed with a vacuum cleaner.
Check the state of the components subjected to high combustion temperatures. Small
deformations do not prevent them from pursuing their good service.

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CARRY OUT THE FOLLOWING OPERATIONS:
* AIR DISTRIBUTOR: clear, if necessary, the air intake holes.
* GRATES: check that there are no objects limiting their movements.
* FANS: DISCONNECT the power supply, DISMANTLE the filter supports (remove the
2blocking screws), DISCONNECT the fans, then REMOVE them. CLEAN the
vanes of the turbines using a brush (COMPRESSED AIR IS NOT ALLOWED).
RE-ASSEMBLE all.
* DUST FILTERS: clean them with a vacuum cleaner and if necessary with water.
* THERMOSTAT: check its correct clearance.
Your dealer can check the adjustment.
* DOOR: check the sealing of the stainless steel seal.
If necessary, your dealer may adjust or replace it. Check the correct operation
of the lock and of the opening safety.
* WINDOW: if, for cleaning, you use a chemical product, PROTECT the exposed
painted surfaces. We recommend the use of the "BG Clean" product
available at your dealer's.
* ASH BOX DOOR: check the state of the seal and if necessary replace it to ensure
correct sealing. Check the operation of the spring clip.
* REFRACTORY BRICKS: a split brick may function quite correctly. However, a
missing piece should lead to the replacement to maintain
an efficient protection of the appliance.
* PAINT: the soiled areas may be restored using aerosols of a special HIGH
TEMPERATURE paint, available at your dealer's.
* LUBRICATION: in frequent use, it is recommended to lubricate every year the
following elements:
Sdoor and door flap: hinges and lock
Sthermostat: control axis.
DO NOT USE NORMAL GREASE. In fact, subjected to high temperatures it would dry up
and lead to a seizing. If necessary, clean thoroughly the surfaces, then apply a GREASE
RESISTANT TO HIGH TEMPERATURES, available at your dealer's.

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D. OPERATION ANOMALIES
ANOMALIES CURES
THE WINDOW GETS DIRTY TOO - Check the humidity of the fuel
QUICKLY - Open the secondary air doser
- Open the passage of the baffles
( cf. "Adjusting the baffles")
VENTILATION - Check the operation of the two motors
Does not function - Check the microswitch
- Check (and replace) the fuse of the variator
- Check the thermocontact (option)
- Check (and repair) the power supply
VENTILATION - Clean or replace the filters
Operates but the flow is low - Clean the vanes of the turbines
Excessive DRAUGHT - Tighten the passage of the baffles
(cf. Installation)
- Consult your dealer
DRAUGHT - Check the chimney
Too low with a possible generation of smoke in (cf. installation instructions)
the room - Remove the possible obstruction
- Have the chimney swept
- Open the passage of the baffles
(cf. "Adjustment of the baffles")
Trouble linked to weather conditions - If this is permanent, consult your dealer
THE FIRE IS NOT BRISK ENOUGH - Check the humidity of the fuel
- Check the thermostat
- Empty the ash box
- Clear the holes of the distributor
THE THERMOSTAT DOES NOT CLOSE ANY
MORE:
- A foreign body prevents the closing of the flap - Remove the foreign body
- Mechanical blocking
- Replace the thermostat
THE THERMOSTAT REMAINS CLOSED:
1. When COLD, the flap only rises from mean - Calibrate the adjustment
positions
2. When COLD, the flap does not rise - Replace the thermostat
THE FIRE CANNOT BE
CONTROLLED:
- The DOOR of the ash box is open or unsealed - Check the correct closing of the ash box door
- The DOOR of the appliance is not sealed - Check the seal, replace if necessary
- Adjust again the door seal
- Adjust again the position of the closing
roller
In case the chimney catches fire, immediately close the door, the ash box door, close
the thermostat and the air doser.

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E. GUARANTEE
DURATION AND LIMITATION
- 6 years guarantee on: the general structure
- 2 years guarantee on: the inner removable parts
- 1 year guarantee on: grates, thermostat, fans and speed variator
- no guarantee on: window, seals, bricks and cast iron plates.
RESERVATIONS
Bodart & Gonay reserve the right to modify their equipments, catalogues, and manuals
independently, at any time and without prior notice.
The validity of the guarantee is cancelled in case the mandatory recommendations of this
manual are not fulfilled.
The intervention under the guarantee are only made through the dealer on presentation of
the purchase invoice.
Parts will be delivered only against the faulty parts.
EXCLUSION
Disasters, breakdown or faulty operation linked to:
- inadequate relation between the nominal power of the equipment and the heat
requirements of the premises;
- a faulty installation or faulty connections;
-a damage to the thermostat through overheating due to intensive use:
* the ash box door is left open
* the ventilation is left off
-an insufficient or excessive draught;
-incorrect use;
-non compatible fuels, destructive and/or damp fuels (treated wood,...);
-consumption exceeding the use limits;
-a lack of maintenance;
-the use of electrical or electronic components that are not approved by
Bodart & Gonay;
-any modification, transformation inside the appliance;
-transport and installation.
Transport and packaging cost.
All costs not previously accepted by Bodart & Gonay.
Costs due to the non-use of the equipment.
TAKING EFFECT

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The guarantee starts on the date written on the invoice. The invoice is the only document
valid for the guarantee.

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INSTALLATION INSTRUCTIONS
Your dealer is the SPECIALIST that BODART & GONAY has chosen to represent them in
your area.
For your SAFETY and SATISFACTION we recommend that you entrust him with carrying
out your installation.
The appliance must be installed in compliance with the rules of building
regulationsand any local regulations. As there are no precise regulations in
Belgium, the French installation regulations (D.T.U. 24.2.2) are applicable.
However, if you want to assume the installation, to avoid any mistakes
allow us to recommend that you:
- refer to the terms of our guarantee;
- take the advice of your dealer.
As it is impossible to mention all the particularities of all cases that may occur, we limit
ourselves to the important points:
A. SAFETY:
-COMBUSTIBLE MATERIALS must be avoided in the proximity of the appliance
and of the connection to the chimney.
Example: a decorative wooden beam above the appliance
requires to be well insulated.
-INSULATING MATERIALS: use preferably materials that withstand HIGH TEMPE-
RATURES (DO NOT USE GLASS WOOL).
Example: around a metal part linking to the chimney, a ceramic insulation is manda-
tory.
-THE SEALING OF THE CHIMNEY and of the linking parts is absolutely required in
order:
*to prevent any combustion gas leak
*not to interfere with the draught of the chimney
-Any COMBUSTION consumes AIR.
Fromthe gap under the door to the direct outside air intake, every one must choose
the solution best adapted to the installation to compensate the slight consumption of
air. Never create a depression in the room where the appliance is installed.
DO NOT SEAL ALL THE AIR INTAKES.

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IF AN EXTRACTION FAN CANNOT BE AVOIDED IN THE SAME PREMISES,
AN ADEQUATE AIR INTAKE MUST BE PROVIDED TO AVOID ANY DEPRES-
SION.
B. RECESS
-Clear the recess for connecting to the chimney, and possibly, for the hot air ducts.
Remove any sinks and dampers.
-Make up the lateral and rear walls with a clearance of 2 cm around the appliance in
order to be able to insert it with its insulation. This will provide a better heat yield,
in particular if the equipment is placed against an outside wall.
-In the case of masonry, it is FORBIDDEN to place masonry on the top of the In-
Fire. The appliance is not load bearing.
C. CHIMNEY
The chimney flue must be made according to the best rules of the trade, here are
the most important ones:
-minimum height 4 m
-the cross section must be neither too small (not less than the output cross section
of the equipment)
or too large (risk of condensation and poor draught)
-the flue must be thermally insulated
-avoid sloping parts, never exceed a slope of 45 ° and avoid any sharp bends of
direction (large curving radius)
- THEOUTPUT OF THE CHIMNEY AND ITS PLACEMENT ARE VERY
IMPORTANT: ask for advice from a chimney expert (any device which reduces the
cross section at the output must be avoided)
-if there are obstacles near the output of the chimney, they must be taken into
account.
-foresee later chimney sweepings
-connect only one appliance per flue
-in case of a double flue:
* choose the best one;
* seal the one that is not used.

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Infire height + 10 mm
-in case of a lateral connection to an existing flue, make one of the following
assemblies:
SOOT TRAP
-TIGHTNESS AND CLEANLINESS are important.
-Seal all the linking parts so that the bottom of the flue socket is placed 10 mm
higher than the top of the appliance that will be introduced.
.
Tightness
-On installation, if necessary install a draught regulator.
The depression must be measured at the time of the first fire. The IDEAL
DRAUGHT is between 10 and 20 Pa (1 to 2 mm water column). If it goes
outside these limits, it is MANDATORY to act on the chimney.
D. HOT AIR DUCT
Two ducts may be connected above the equipment to heat contiguous rooms.
To install these ducts, limit their length, avoid as much as possible any bends and
changes of direction, the resulting decrease of speed reduces the efficiency of the hot
air output at the end of the ducts.

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According to the requirements and the risk of heat loss, insulation of these ducts is
useful.
Remark:an efficient hot air circuit requires an air return so as to avoid depression in
the room where the appliance is. For each room concerned, a ventilating
grid placed near the ground allows the cooled air to come out of the place in
order to complete its circuit.
E. ELECTRICAL INSTALLATION
Connexion:
-Remove the filter support on the side you chose, corresponding to the power supply
(unscrew the 2 mounting screws, turn and remove the filter support).
-Bring the flexible power cable in front of the opening foreseen in the equipment.
Provide a sufficient length for the connection and to facilitate possible later
interventions. If, for the connection, you have removed the protecting stops, place it
on the connector of the second fan that is not used.
Stop to be placed on free connector
-Avoid using the same circuit as those of the audio and video equipment.
-Do not install the variator near these household equipments.
BEWARE! The use of a variator and/or internal fuse which is not approved by Bodart &
Gonay risks the exclusion to the right of the guarantee on the whole of the electrical
equipment.

MICRO-SWITCH
123
4
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Diagram of the electrical connection in the in-fires (without thermocontact)
1. Blue 2. Brown 3. Black 4.Yellow-green
Electrical connection diagram for the infires (with thermocontact)
1. Blue 2. Black 3. Yellow-green 4. Brown
Position of the fans:
The fans are mounted on self-gripping pads. TAKE CARE TO AVOID ANY DIRECT
CONTACT BETWEEN THE FAN AND THE STRUCTURE OF THE APPLIANCE TO
AVOID THE TRANSMISSION OF VIBRATIONS.
Dismantling of the microswitch
-The microswitch is situated in the left fan case.
-Disconnect the power supply.
-With the door closed, and door flap open, dismantle the left filter frame.

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-Unscrew the two screws.
SCREWS
F. ADJUSTMENT OF THE BAFFLES
The baffle system is designed to adapt the appliance to the draught of the chimney. The
baffles rest on square supports.
Baffles from the most closed to the most opened position (pictures 1 to 3).