Broseley eVolution 5 Manual

Installation & Operating
Instructions
Covering Models:
eVolution 5
Wood Burning Stove
(Standard, Deluxe and Log Store Versions)
Tested to EN 13240
These appliances must be installed and commissioned by a HETAS registered engineer
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Contents
Introduction 3
Packing List 3
Health & Safety 4
Specifications 5
Dimensions 6
Hearth Requirements & Clearances 7
Chimney Requirements 8
Combustion Air Requirements 9
Assembly 10
Assembly for Smoke Exemption 12
Stove Operation
Controls Layout 13
Controls Explained 14
Air wash System 14
Ash Pan 14
Recommended Fuels 15
Lighting the Stove
Kindling Stage 16
Burning Wood 17
Smoke Exempt Requirements 18
Warning Notes 20
Maintenance
Ash Removal 21
Chimney Fires 21
Chimney Sweeping 21
General Stove Cleaning 21
Glass Cleaning 21
Annual Stove Service 21
Trouble-shooting 22
Commissioning Form 23
Spare Parts 24
EC Declaration 25
Annual Service Record 26
Warranty 27
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Introduction
May we take this opportunity to thank you for choosing one of our stoves.
These appliances are designed to burn wood logs and wood derived fuels. It is essential
that your wood has been seasoned to ensure that it is sufficiently dry for burning. You can
determine the moisture content of your logs by using a digital moisture meter, your logs
need to be below 20% moisture content before they are considered dry enough for
burning.
Never burn wood that contains paint, glue or any other chemicals
See the section “Lighting the Stove” for further details. After reading this document, if there
is anything you are unsure about, please contact your dealer or our Technical Support
Department.
These instructions cover the basic principles to ensure the satisfactory installation of the
stove, although detail may need slight modification to suit particular local site conditions. In
all cases the installation must comply with current Building Regulations, Local Authority
By-laws and other specifications or regulations as they affect the installation of the stove.
It should be noted that the Building Regulations requirements may be met by adopting the
relevant recommendations given in British Standards BS 8303, BS 6461 and BS 7566 as
an alternative means to achieve an equivalent level of performance to that obtained
following the guidance given in Approved Document J.
Please note that it is a requirement under the Broseley Fires warranty system that
the installation of the stove is carried out 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.
Packing List
1x Cast Iron/Steel Stove Seperate Box Containing: Deluxe Models Only:
1x Rear Firebrick 1x Spigot & Fixings 1x Black Glass (Lid)
1x Air Firebrick 1x Spigot Ring
1x Baffle 1x Ash Tool & Glove Set
2x Baffle Spacers 1x Smoke Exempt Washer
2x Side Firebrick 1x Instruction Booklet
1x Grate & Grate Support
1x Ashpan
All parts will be inside the main stove body upon delivery.
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Health & Safety
Special care must be taken when installing the stove such that the requirements of the
Health and Safety at WorkAct are met.
Installation
This appliance MUST be installed and commisioned by a HETAS registered installer in
England and Wales and a fully qualified Heating Engineer in Scotland and Ireland.
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 wash immediately with plenty of water.
Asbestos
This stove contains no asbestos. If there is a possibility of disturbing any asbestos in the
course of installation then please seek specialist 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.
CO Alarms
Building regulations require that whenever a new or replacement fixed solid fuel or
wood/biomass appliance is installed in a dwelling an audible carbon monoxide alarm must
be fitted in the same room as the appliance. Further guidance on the installation of the
carbon monoxide alarm is available in BS EN 50292:2002 and from the alarm
manufacturer’s instructions. Provision of an alarm must not be considered a substitute for
either installing the appliance correctly or ensuring regular servicing and maintenance of
the appliance and chimney system.
Fire Guards
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 6539.
Aerosol Sprays
Do not use an aerosol spray on or near the stove when it is alight.
Operating Tool & Gloves
Always use the operating tool and glove provided when handling parts likely to be hot
when the stove is in use.
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Specifications
In the UK these stoves have been approved by HETAS Ltd as intermittent heating
appliances for burning manufactured or naturally occurring smokeless fuels and wood logs
only.
Heat Output: 5 kW
Weight: 100 Kg /139 Kg with Log Store
Flue Gas Mass Flow: 3.3 g/s
Flue Gas Temp: 215°C
Flue Draft Required: 12-16 pa
Flue Outlet Size: 6” / 150mm
Efficiency: 85.5%
European standards need to be complied to when installing this appliance.
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Dimensions
All dimensions are in millimetres
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Hearth Requirements & Clearances
These appliances are suitable for non-combustible hearths with a minimum
thickness of 12mm, they do not require a full constructional hearth.
Your stove must be installed on a solid, level non-combustible hearth. The hearth
protrusion in front of the stove to carpets or wooden floors must be at least 300mm. As it is
possible, that on opening the door of the stove for fuel to fall out, a fender must be fitted if
the hearth is flush with the finished floor level. These are just a few hearth specifications.
Please refer to Building Regulations Approved Document J (Hearths) for more specific
details.
Clearances
The stove requires the following clearances around it to ensure the heat is released into
the room and to allow sufficient combustion air flow. Acombustible material clearance is
given to prevent damage to any items that may be affected by heat.
Stove Clearances A B C Above
Non-Combustible 100mm 100mm 300mm 200mm
Combustible 400mm 180mm 300mm 600mm
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Chimney Requirements
This appliance must not be fitted into a chimney serving another heating appliance. It is
most important that there is no obstruction in the flue or chimney. Please ensure that any
existing chimney is clear of obstruction and swept clean immediately before installation of
the new stove. If the chimney has been used for an open fire it is recommended that it be
swept for a second time having been used for a month following installation.
A flue draught minimum of 12 Pascals to a maximum 16 Pascals is required for
satisfactory appliance performance. A properly built masonry or factory constructed
chimney (with a minimum vertical height of 5 metres) should ensure a consistent draught
(draw). 45° bends can be used in the flue run (maximum of four bends) you will need to
add an extra 1 metre of vertical flue height for each bend.
The flue draught should be checked under fire at high output and if it exceeds the
recommended maximum, a draught stabiliser must be fitted so that the rate of burning can
be controlled, and to prevent over firing (See section “Warning Notes”). If you have any
doubts about the suitability of your chimney, consult your local dealer/stockist or engineer.
If your flue draft is below the minimum recommendation then it may be neccesary to
increase the vertical chimney height, add additional flue insulation or possibly add a
special cowl to the top of the chimney (e.g. anti down draft cowl to eliminate wind induced
down draft).
The outlet from the chimney should be above the roof of the building in accordance with
the provisions of Building Regulations Approved Document J.
If installation is into an existing chimney then it must be sound and have no cracks or other
faults which might allow fumes into the house. Older properties, especially, may have
chimney faults or the cross section may be too large i.e. more than 230 mm x 230 mm.
Remedial action should be taken, if required, seeking expert advice, if necessary. If it is
found necessary to line the chimney then a flue liner suitable for solid fuel must be used in
accordance with Building Regulations Approved Document J.
If there is no existing chimney then either a prefabricated block chimney in accordance
with Building Regulations Approved Document J or a twin walled insulated stainless steel
flue to BS 4543 can be used. These chimneys must be fitted in accordance with the
manufacturer’s instructions and Building Regulations.
If a flexible liner is required the liner diameter must not be less than 6”.
Any bend in the chimney or connecting fluepipe should not exceed 45°. 90° bends are not
permitted. For top flue installations it is possible to sweep through the appliance by
removing the internal baffle however it is recommended that you provide adequate access
(e.g. easily accessible soot door). For rear flue connection we recommend the use of a tee
section, the bottom of the tee should be capped to catch soot and debris.
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Combustion Air Requirements
In order for the stove to perform efficiently and safely there should be an adequate air
supply into the room in which the stove is installed to provide combustion air. This is
particularly necessary in modern houses where drafts have been almost eliminated by
double glazing etc.
Under UK building regulations any appliance over 5kW MUST have a fixed
permanent air vent (see building regulations approved document J for further
information).
There must not be an extractor fan fitted in the same room as the stove as this can cause
the stove to emit fumes into the room. It is necessary to install a wall vent to provide the
necessary combustion air and to prevent the depletion of oxygen in the room.
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Assembly
The diagram below shows the stove with all internals taken out.
To install the internals simply follow the numbered sequence 0-11 and to remove simply
reverse this process.
Please note the item numbered (1) is a steel secondary baffle, this is NOT a control and
should be fitted fully pushed towards the back of the stove. The baffle should be left in at
all times, it is only removable for chimney sweeping purposes the same as item (4).
Please Note on Item 6 (Airbrick) the smaller holes should face the glass.
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Assembly
It is possible to convert the stove between standard and log store version (and vice
versa) . The standard base can be unbolted (as shown below) and the stove installed onto
the log store base. Simply reverese this process to change the stoves log base for a
standard one.
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Assembly for Smoke Exemption
When installing this appliance into a smoke control area you will need to change the
washer that sits behind the air slider to the smoke exempt washer (supplied). The smoke
exempt washer ensures a constant supply of combustion air to meet smoke exempt
requirements.
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Controls Layout
The diagram below shows the position of the air control, this control needs to be operated
correctly to control the combustion rate of the stove.
This air control is classed as the “Secondary Air Intake” as it brings air in above the
grate. See the following section for a more detailed description of how this control works.
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Controls Explained
Fire needs air to burn therefore the stove is fitted with an air control that allows you to
regulate the amount of combustion air therefore controlling the burn rate within the
appliance.
Secondary Air Intake
The secondary air intake is located on the front of the stove below the door, it is in the form
of a slider. Having the slider pushed to the right indicates that the air intake is in the
closed/minimum position and to the left indicates it is in the fully open/maximum position.
In smoke controlled areas you should fit the smoke exempt washer behind the control, this
will prevent the control from fully closing.
Air entering through this control is directed through the holes in the air firebrick and also
down the inside of the glass creating the AIRWASH system – see below. The air wash
system reduces the amount soot and particle's making contact with the glass. This control
is used at initial lighting and to control the burn rate of your wood.
The sections LIGHTING THE STOVE & BURNING WOOD gives a step by step guide on
how to operate this control.
Air wash System
Air wash is a system where secondary air is drawn into the stove (by combustion) through
the secondary air control and is deflected down the back face of the glass, thus preventing
the smoke coming into contact with the glass. It does not mean that you will never have to
clean the glass, but substantially lengthens the periods between having to do so. The air-
wash system works best when burning dry wood. Wet wood will produce more deposits
on the glass. Also, deposits will form on the back of the glass when the stove is operated
on low heat for extended periods (where fuel is only just smouldering).
Ash Pan
The ash pan can be accessed by lifting out the grate. The tool can be used for this task. It
is recommended that this is done when the stove is cold and not alight.
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Recommended Fuels
This appliance has obtained approval from HETAS Ltd., for burning –
* Split Hardwood logs not exceeding 35cm in length and not over 20% moisture content.
Approval does not cover the use of other fuels either alone or mixed with the suitable fuels
listed above.
Do NOT burn wet wood, This will give a poor heat output and will cause heavy deposits
of soot and tar to accumulate on the glass and throughout the stove and flue. The coating
of soot and tar in the chimney is volatile creating a high risk of chimney fires. A growing
tree contains a high percentage of water, the wood needs to be dried out (seasoned)
before it is suitable for burning (this can take several years). Wood logs are best stored in
a stack, sheltered from the weather, in a well ventilated area and raised off the ground.
This allows the air to circulate and prevents mildew.
Do NOT burn Pallet Wood, or any other wood containing glue, paint or any other
chemicals. Burning such fuel will result in damage to your appliance, any such damage will
not be covered by the products warranty.
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Lighting the Stove
Curing
On initial firing you will notice a very pungent odour, this is caused through the curing of
the paint, we recommend starting with short burning sessions (with smaller quantities of
fuel) and build up gradually to allow the components of the stove to settle. Opening doors
and windows will allow the paint curing odour to dissipate and to allow ventilation into the
room. Curing times can vary but typically should take around 8-12 hours (operation at
nominal output) to complete.
Kindling
Stage1
With the Secondary air intake slider (below door) in the fully open position and the door
open, start your fire using twists of newspaper (or scrunched up balls). Form a bed on the
grate using the newspaper, then add a generous amount of dry kindling onto the
newspaper. Ensure their is sufficient air gaps between the kindling (a criss cross or
pyramid style pattern is ideal to accomplish this). Firelighters can also be used for this
task.
Kindling ---------------
Newspaper -----------
Stage 2
Ignite the paper underneath using a match or suitable fire-lighter. Allow the paper and
kindling to burn until it reduces down into hot embers. If the fire is dying during this stage
the door can be closed but not latched leaving a small gap for extra combustion air.
Stage 3
Add another generous load of dry kindling and allow to burn down.
It may be necessary to repeat stage 3 if the chimney is cold or if you find you have smoke
entering the room. This stage is vital for getting heat into the chimney which will create the
draw that takes the smoke away, we would expect this stage to take between 15-20
minutes.
It is critical that you do not leave the stove during the entire lighting and kindling
stage. See Burning wood section for the next steps in the sequence.
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Burning Wood
Once you have kindled your stove (see previous page) and your chimney (flue) is
sufficiently heated, you are now ready to start adding you logs.
Stage 4
Place 1-3 small logs onto the bed of hot embers using the gloves provided, close the door
but leave the Secondary Air Control in the fully open/maximum position. Allow the logs
time to fully ignite and turn black.
Stage 5
Once the smaller logs have burned down you can now add 1-2 larger ( or full size) logs,
allow time for the logs to fully ignite (Turn black) then close down the Secondary Air Intake
as required. You can now control the burn rate of the stove using the secondary air intake.
You are looking for a controlled flame (not smouldering in the embers or licking around the
lid) this is mostly visual although a flue pipe thermometer will help you determine the
amount of air required and is recommended for the initial lightings.
Stage 6
Refuel as and when required. Open the secondary air intake fully when refuelling and
allow the new fuel to ignite (Turn black). Control the combustion as per stage 5. Take care
to open the door gradually as flames may lick out and always use the gloves. Try to avoid
closing the Secondary air control fully (as this will cause the stove to fill up with smoke). If
you no longer want to keep the fire going simply allow it burn out.
Please note this is the standard lighting sequence, if you are in a smoke control
zone there is an alternative sequence which can be found in the SMOKE EXEMPT
REQUIREMENTS section – next page.
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Smoke Exempt Requirements
The eVolution 5 Wood burning stove has been tested by GASTEC under the PD6434
standard and has passed the emission requirements for exemption under the Clean Air
Act. Subsequently it has been exempt for use in smoke control areas when burning wood
only.
Smoke emissions from the appliance were measured over three main air control settings
representing high, medium and low outputs. The three output test conditions undertaken in
the present report were conducted with the air control (i) fully open – high output, (ii)
85% open – medium output and (iii) 70% open – low output
The low setting used was not the minimum setting for the control, the minimum air control
setting would give very poor smoke reduction since it was possible to starve the appliance
of air almost completely. Alow setting that maintained clean combustion was determined
and used as the low output setting (70%).
There is a requirement for the door to be left ajar for 5 minutes immediately after refuelling.
This is to ensure that flames are well established on the newly charged logs and that
they become fully blackened. Additionally, for medium and low output burning, the air
control must be maintained at 100% open for the first 5 minutes after refuelling at which
time it is possible to adjust to the required settings as identified above.
Ignition Sequence (Smoke Exempt Areas)
The procedure adopted for ignition is to build a bed in stages and to warm the body of the
appliance and the chimney as quickly as practicable.
Firstly kindling, weighing approximately 1 kg will need to be lit (using a chemical firelighter
is recommended) with the air control fully open. The door must be pushed against the
appliance but then left ajar.
After about 10 minutes, when the fire from the kindling is beginning to die back, two small
logs can be added. When these are alight and fully blackened, the door can be closed.
This, typically, takes approximately a further five minutes.
When the fire is again beginning to die back, a full load of two logs, weighing about 1.3
1.4 kg, can be added: typically this takes 20 – 25 minutes from the start of the ignition
sequence. The air control must be maintained in its fully open position for the remainder of
the ignition sequence. Once the fuel has blackened the fire can then be allowed to burn
down to a suitable condition at a preferable air slider position. For start of further re fuelling
apply sequence in the previous 2 sentences.
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Smoke Exempt Requirements
1. It is important to follow the smoke exempt instructions in order to achieve clean
burning and to maximise the efficiency from the stove
2. Do not leave the fire unattended after refueling until flames are well established on
the newly charged logs
3. Refuelling on to a low fire bed 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
4. Fuel overloading The maximum amount of fuel specified in this manual should not
be exceeded, overloading can cause excess smoke.
5. 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.
6. Dampers left open Operation with the air controls or dampers open can cause
excess smoke. The appliance must not be operated with air controls or dampers
door left open except as directed in the instructions.
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Warning Notes
Over-Firing
It is extremely important that you do NOT leave the air control in the fully open position for
extended periods or run the appliance with the door open. Leaving the air control fully open (or
running with the doors open) will lead to “over-firing”. Over-firing is caused when too much heat is
generated within the fire chamber, this will lead to warping, buckling and general damage to the
stove and its internal components. Over-firing can also be caused by an excessive flue draft.
PLEASE NOTE ANY DAMAGE TO THE APPLIANCE CAUSED THROUGH OVER-FIRING WILL
NOT BE COVERED BY THE WARRANTY.
Fumes
Properly installed, operated and maintained, this appliance will not emit fumes into the dwelling.
Occasional fumes may occur whilst de-ashing and re-fuelling. However, persistent fume emission
is potentially dangerous and must not be tolerated. If fume emission does persist, the following
immediate actions should be taken:-
a) Open doors and windows to ventilate the room
b) Let the fire go out or eject and safely dispose of fuel from the appliance
c) Check for flue or chimney blockage and clean if required
d) Do not attempt to relight the fire until the cause of the fume emission has been
Identified and corrected. If necessary seek expert advice
Firebricks
Vermiculite is an industry recognised robust fireproof material which is used by many stove
manufacturers to produce internal firebox linings (firebricks). With care vermiculite firebricks will
give many years of faithful service.
It is important that care is taken whilst refueling your stove in order to protect the internal
vermiculite parts from premature failure.
Never throw or drop logs into your stove as this will potentially damage your firebricks and may
also result in logs bouncing out of the appliance (creating a possible fire risk). Open the door an
inch initially (allowing the fire to settle) then slowly open the door and gently place the log(s) onto
the grate. Always use the glove (provided) when refueling to avoid the common scenario of
dropping the logs in quick (because it’s hot).
Take care when clearing the ash and using the poker tool not to strike and potentially damage your
firebricks.
Always take care when removing the firebricks to avoid damaging them. It may be necessary to
remove the firebricks during general maintenance and chimney sweeping.
Impact damage is the most common cause of cracked vermiculite firebricks; however it is also
possible to crack the firebricks if you over fire your appliance.
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