Broseley SUPER MAX User manual

© 2008-2009 Broseley Fires Ltd
INSTALLATION AND OPERATION
INSTRUCTIONS FOR WOODBURNING:
MAX, JUNIOR, SUPER MAX & SUPER JUNIOR
TESTED TO EN 13240
This appliance must be installed and commissioned by a fully qualified, registered engineer.
A “Declaration of Completion” Certificate must be obtained for the installation and retained by the end user.
Failure to comply with these requirements may void the warranty.
PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING, OPERATING OR SERVICING
THIS APPLIANCE. THESE APPLIANCES ARE DESIGNED TO BURN WOOD ONLY
TJ-issue-09-B

© 2008-2009 Broseley Fires Ltd
Congratulations on buying a product distributed by Broseley Fires Ltd.
INTRODUCTION
Please read the following instructions carefully to get the best from your new purchase.
The keys to safe, successful and efficient wood burning are good planning, correct installation (by a qualified
heating engineer) and proper operation.
Modern homes have better levels of insulation and are more energy efficient, with more effective and better seals
on doors and windows. This makes our homes easier to heat, but also means that solid fuel appliances must be
more carefully designed so that they will function correctly in the energy efficient, modern homes of today. The
more energy efficient a house is, the less fuel is required to heat it. Less fuel use means less impact on the
environment.
The operation of our appliances, so that they do not produce excessive smoke (beyond the initial light up and
reloading periods) is most important. When our appliances are not smoking, it is an indication that they are being
operated correctly and are burning efficiently. The escape of any unburnt particles and some gases into the
atmosphere are the cause of air pollution.
Our appliances are designed to ensure that the combustion of all gases and particles takes place within the
firebox, to maximise the heat output of the appliance and to minimize the discharge of particulate emissions to the
atmosphere.
It is important therefore, for appliances to be operated in accordance with our instructions in a manner that
maintains a high temperature in the firebox with an adequate supply of air to ensure efficient combustion. A good
indication of efficient combustion is a bright lively flame in the firebox. A dull flame or smoldering fire indicates
poor or incomplete combustion.
To maintain adequate heat in the firebox, it is very important to use dry, well seasoned wood with less than 20%
moisture content. The wood must be correctly sized for the particular appliance and it also helps to have at least
three or four pieces burning at the one time to assist the combustion process.
Adding single pieces of unseasoned or wet wood to a fire will reduce the firebox temperature and prevent
adequate combustion. This will result in increased smoke emissions causing the flue and internal components of
the appliance to become blocked with tar and creosote more quickly. The tar and creosote deposits in the
chimney will fuel a chimney fire.
Please note that it is a requirement under the Broseley Fires Ltd’s warranty system that the
installation of the stove is carried out under 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.
A “Declaration of Completion” Certificate must be obtained for the installation and retained by the end user.
Failure to comply with these requirements may void the warranty.
PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS APPLIANCE.

© 2008-2009 Broseley Fires Ltd
INDEX
1. TECHNICAL DATA
2. MANUFACTURERS DECLARATION
3. HEATABLE AREA (VOLUME)
4. KEY ENVIRONMENTAL CONSIDERATIONS
5. TECHNICAL DESCRIPTION
6 THE ‘AIR’ CONTROL
7. THE ‘RIDDLING GRATE’
8. USING YOUR STOVE – IMPORTANT NOTES
9. FUEL OPTIONS
9 A BURNING WOOD
10 INITIAL BURNING & CURING OF THE STOVE
11. LIGHTING AND MAINTAINING A LOG FIRE
13 ASH REMOVAL – CLEANING OUT THE ASH
14 WOOD ASH DISPOSAL
16 OPERATING IN TRANSITION PERIODS (Summer)
17 A DAILY CARE
17 B CLEANING AND MAINTAINING THE APPLIANCE:
17 C CAST IRON
17 D ENAMELED SURFACE
17 E GLASS CLEANING
17 F BROKEN GLASS
17 G ASH REMOVAL
17 H FLUE MAINTENANCE
17 I ROPE SEALS
17 J AIR CONTROLS
18 SPARES
20 INSTALLATION OF THE APPLIANCE
21 FLUE REQUIREMENTS
22 LINING THE FLUE
22 A FLUE TERMINATION
23 PROVISION OF A NOTICE PLATE
24 SITING THE APPLIANCE
25 HEARTH REQUIREMENTS
26 STOVE CLEARANCES
27 ADDITIONAL VENTILATION
28 CHIMNEY FIRE
APPENDIX A POSITION OF THE INTERNAL BAFFLE PLATE (JUNIOR)
APPENDIX B POSITION OF THE INTERNAL BAFFLE PLATE (MAX)
APPENDIX C POSITION OF THE INTERNAL BAFFLE PLATE (SUPER MAX & JUNIOR)
APPENDIX D TECHNICAL DRAWING FOR THE MAX
APPENDIX E TECHNICAL DRAWING FOR THE JUNIOR
APPENDIX F TECHNICAL DRAWING FOR THE SUPER JUNIOR
APPENDIX G TECHNICAL DRAWING FOR THE SUPER MAX
POSITION OF THE SMOKE DEFLECTORS
TECHNICAL DRAWINGS FOR THE APPLIANCES
ANNUAL SERVICE RECORD
LIMITED WARRANTY

© 2008-2009 Broseley Fires Ltd
1. TECHNICAL DATA
PLEASE REFER TO ATTACHED TECHNICAL DRAWING FOR OTHER DIMENSIONS NOT
LISTED HERE
MAX JUNIOR SUPER MAX SUPER JNR
Nominal heat output (kW) 6 5 6 5
Efficiency % 70 75
80.3 79.5
Flue diameter MINIMUM
*an adaptor is required 5 INCH 5 INCH 5 INCH 5 INCH
Maximum load wood (Kg)
(to maintain nominal output) 1.9 1.4 1.9 1.49
Flue draught Pressure (Pa)
(tested when hot) WOOD
(mbar/Pa)
0.11
11 0.11 11 0.12 12 0.12 12
Temperature of exhaust gas in
ºC (wood) 360 240 226 226
Type of grate Externally operated riddling grate
Stove height in mm 820 780 811 771
Stove width in mm 400 360 402 360
Stove depth in mm 450 400 482 415
Wei
g
ht in K
g
76 59 71 59
2 MANUFACTURERS DECLARATION
Subject: Asbestos and cadmium
It is declared that all our products are assembled with materials that do not contain any asbestos or its derivatives
and that the materials used for welding do not contain cadmium in any form.
Subject: Regulation CE no. 1935/2004
It is declared that in all our products, the materials that are destined to come into contact with foodstuffs are
adapted to food use in line with the above regulation.
3 HEATABLE AREA (VOLUME)
The heating capacity of rooms according to EN13240: 2001 + A2: 2004 for buildings in which the insulation is
below the levels recommended in regulations is:
MAX JUNIOR SUPER MAX SUPER JNR
(30 kcal/m3) -Well insulated: 172m³ 143m³ 195m³ 124m³
(40 kcal/m3) -Average insulation: 129m³ 107m³ 95m³ 73m³
(50 kcal/m3) -Poor insulation: 103m³ 86m³ 65m³ 48m³
With adequate insulation the above values will be higher. With temporary use, when breaks exceed eight hours,
the heating capacity is reduced by around 25%.
4 KEY ENVIRONMENTAL CONSIDERATIONS
To minimize the impact on the environment the following issues need to be considered when proposing to install a
solid fuel appliance:
•Local authorities (Councils) must be consulted for any restrictions that may apply to the use of solid fuel
appliances in certain areas such as smoke free zones.
•The appliance must be correctly sized to suit the space and necessary clearances must be strictly
adhered to.
•The appliance and flue system must be correctly installed to the current regulations in force at the time.
•The appliance must be correctly operated.
•The appliance and flue system must be properly maintained.
•It is also important to ensure that the dwelling to be heated is well insulated and is as energy efficient as
is practical before a heating appliance is chosen and installed.
•The correct fuel must be used.

© 2008-2009 Broseley Fires Ltd
The selection, installation, correct use and maintenance of solid fuel appliances and flue systems are discussed in
more detail in the following sections of these instructions.
5 TECHNICAL DESCRIPTION
These appliances have been developed to burn wood at a very efficient rate. The figures quoted here are from
test firings using beech logs with a moisture content of less than 20%. This appliance can burn brown coal and
briquettes made of Lignite.
The appliance is engineered using the latest manufacturing techniques and modern computerized machinery.
6A THE ‘AIR’ CONTROL MAX & JUNIOR
The stove is fitted with an air control that adjusts the flow of combustion air into the unit. It is very important that
the control is fully understood in order to achieve the best results from your stove.
When operating the control, ensure that they are used in small increments and not changed by large amounts
suddenly. Do not use them like an on – off switch.
•PRIMARY AIR CONTROL
The primary air control (see FIG. 1) is found on the front of the ash door which is under the main door. It is in the
form of a spinner. Turning the spinner anti-clockwise opens the air control and lets more combustion air into the
appliance; to slow the combustion rate down, turn the spinner clockwise.
There is also a control for the riddling grate. Please see CHAPTER 7 below for an explanation.
PRIMARY AIR
CONTROL
(SPINNER)
FIG. 1

© 2008-2009 Broseley Fires Ltd
6B THE ‘AIR’ CONTROL SUPER MAX & SUPER JUNIOR
The stove is fitted with an air control that adjusts the flow of combustion air into the unit. It is very important that
the control is fully understood in order to achieve the best results from your stove.
When operating the control, ensure that they are used in small increments and not changed by large amounts
suddenly. Do not use them like an on – off switch.
•PRIMARY AIR CONTROL A
The primary air control (see FIG. 1A) is found on the front of the ash door which is under the main door. It is in the
form of a spinner. Turning the spinner anti-clockwise opens the air control and lets more combustion air into the
appliance; to slow the combustion rate down, turn the spinner clockwise.
•SECONDARY AIR CONTROL B(Airwash Control)
The secondary air control (see FIG 1A) is in the form of a slider control located above the fire box door. This
control works by allowing air to come in over the fuel. This control is fully open when moved to the right and fully
closed when moved to the left. The secondary air control also works as an air wash control to maintain a clean
glass.
Fig 1A

© 2008-2009 Broseley Fires Ltd
7. THE ‘RIDDLING GRATE’ (SEE FIG. 2)
Use the riddling mechanism to shake the dead ash from the top of the grate into the ash pan below.
It is in the form of a pull-push lever and is located under the main door, to the right of the primary air control.
Never allow excessive ash to build up on the grate as this will be detrimental to the heat output of the appliance
and will cause accelerated wear of the grate. The efficiency of the appliance will also be affected.
MAIN DOOR
ASH DOOR
8. USING YOUR STOVE – IMPORTANT NOTES
This appliance must be installed and commissioned by a fully qualified, registered engineer.
•Serious damage can result if the appliance is left running with the air controls fully open for extended periods.
•Make sure that none of the doors are left open while the appliance is in operation.
•Never leave the appliance unattended during the initial lighting sequence.
•Do not attempt to open the door immediately after igniting the fire. This could cause a flame flash out.
•Always wear the protective gloves when operating the appliance.
•Never burn enhanced fuels such as ‘Petrocoke’
•Do not overload the appliance with fuel.
•Never use flammable chemicals or fluids, such as gasoline, to light a fire.
•Using the appliance on a very low output will cause excessive amounts of tar to build up inside the flue and
can be a serious fire risk, as this will fuel a chimney fire.
•If you regularly run the appliance at a very low output, you will need to have the flue cleaned more regularly.
•Never overload the stove (consult the technical table- maximum allowable quantities)
•We advise that you have the appliance serviced annually by a competent heating engineer before the
beginning of a new heating season.
•Do not cover the permanent air vent that your heating engineer has installed; this is necessary for the correct
combustion of the appliance and your safety.
IMPORTANT: The calorific (heat) output of your appliance is affected by the operation of your chimney.
If it has a very strong draw, then you will need to adjust the air controls to allow less air for combustion through
the appliance. The slow draw on a chimney will not give ideal results and will require a more exact adjustment of
the controls for correct combustion. If the flue draught is greater than the figure recommended by the
manufacturer, it will be necessary to fit a flue draught stabilizer.
Make sure that children are aware of these dangers and keep them away from the stove while it is in use.
9 FUEL OPTIONS
These appliances have been developed to burn wood. The results quoted in our literature are from test firings
using beech logs with a moisture content of less than 20%. Coal should never be burnt in these appliances The
grates and internal components of these appliances have not been developed for burning .
Never burn ‘enhanced’ fuels such as ‘Petrocoke’.
RIDDLER CONTROL
FIG. 2

© 2008-2009 Broseley Fires Ltd
9 A BURNING WOOD
Hardwoods have a far greater calorific value than softwoods, weight for weight. Any wood needs to be stored in a
well ventilated shelter to season it. Wood used in this appliance must have a moisture content of less than 20%.
Damp or wet wood will quickly form tar deposits on all the internal areas where the combustible gasses travel,
preventing the efficient release of heat from the appliance. The inside of the chimney/flue will also be coated,
there is a greater risk of a chimney fire occurring.
When selecting wood, also take into consideration ease of splitting, ease of ignition and burning, how much
smoke it produces and its "coaling" qualities. "Coaling" refers to the ability of a species of wood to form a long-
lasting bed of hot coals when burned. Coaling qualities improve with wood of a higher density. Wood is not a long
burning fuel and so it is not always possible to keep the stove in overnight.
10 INITIAL BURNING AND CURING OF THE APPLIANCE
The first time that the appliance is lit, there will be an odour given off. This is the components of the appliance
curing. It will be necessary to ventilate the room in which the appliance is sited.
The first firing needs to be done carefully to allow all of the components of the appliance to settle gradually. Never
try to run the appliance flat out the first time you light it. It will be necessary to keep the fire burning for longer
periods rather than short periods the first four to five times. This will be the best way to achieve correct settling of
the appliance. Do not burn the appliance at an accelerated rate, a steady burn is all that is required.
Gradually build up the output of the fire so that no sudden stresses are put on the components of the appliance.
During the first lightings, nothing should be leant against the stove and in particular on the varnished
surfaces. The varnished surfaces must not be touched during the initial curing process.
11 LIGHTING AND MAINTAINING A LOG FIRE
•Use scrunched up paper and dry kindling to start the fire. Lay these on the grate. An alternative is to use
fire lighters.
•Open the air control to the fully open position. It will take a short time for the fire to establish itself.
•When the fire is burning hot, add small pieces of very dry wood, preferably hardwood as these generate
better embers.
•Keep the air control fully open till a bed of hot, glowing embers is established.
•Once you have some red hot burning embers, open the loading door and rake the embers evenly over
the grate before adding larger pieces of wood.
•We suggest that you do not fully load the appliance until you have become completely familiar with the
operation of the air control.
•Do not open the loading door too quickly when reloading the appliance as this can cause flames to flash
out the door.
•A typical load will be 1.4 KG; this will maintain the output of this appliance.
•Do not burn painted or varnished woods, MDF, oak bark or any wood with more than 20% humidity.
•It will be necessary to release the ash using the ‘riddling grate’ as this appliance has only one air control.
13 ASH REMOVAL
The removal of ashes should be done when the appliance is cold.
Whether you burn logs or coal, you will be left with ashes. They must be removed periodically for the correct and
efficient operation of your appliance. Don’t wait till the ash pan's completely full. The frequency of this ash removal
will depend on the type of fuel being burned, i.e. Softwood, hardwood, coal and briquettes; all create differing
amounts of ash.
Keep in mind that cleaning your appliance boosts its efficiency, as ash, soot or tar deposits will block the heat
from coming out of the appliance.
Excess ash in the pan will cause a coal fire to go out and may cause severe damage to the grate. It may also
prevent the ash door from being shut correctly.
Take care when removing the ash, as small bits of hot embers can stay dormant for long periods when buried in
ashes. These will then flare up again when exposed to oxygen. Use a metal container to carry any ash.
For your own protection, a pair of heat proof gloves and a dust mask may be necessary.

© 2008-2009 Broseley Fires Ltd
14 WOOD ASH DISPOSAL
The best thing to do with your ashes is to put them in your garden. Wood ashes are high in potassium, calcium,
sodium, magnesium, and phosphorus.
Wood ash will make your soil more alkaline, so apply it appropriately for your soil.
If you have no garden, you can dispose of completely cold ash with your household trash.
Place it in a tightly closed bag to keep it contained. Use the same precautions as disposing of coal ash.
16 OPERATING IN TRANSITION PERIODS (Summer)
When the outside temperature gets hotter than the temperature within the property, there is a strong possibility of
the flue working in reverse. If the appliance is not lit, this will cause the draught of the flue to travel in a downward
direction and the smell of smoke will be obvious in the room.
If you experience problems lighting the appliance because of the greater outside temperature, then it will be
necessary to warm the flue before loading the appliance with kindling. There are various methods for this
procedure. Ask your local supplier or registered chimney sweep for advice.
If the fire is lit, the heat output of the appliance is often reduced and the exhaust gases may not come out the
chimney completely. This can cause them to come back into the room. In this case:
•shake the embers more frequently,
•increase the air for combustion and
•only load a reduced quantity of fuel.
This will help to keep the chimney hot and working efficiently.
Check that all the seals of the appliance are in good order and that the connections to the chimney are also
sound.
17 A CLEANING AND MAINTAINING THE APPLIANCE
The appliances have three main surface finishes; these should be cleaned when the appliance is cool. Please
follow any instructions to the letter for any special cleaning agent that you may use. Ash removal and chimney
maintenance are also important areas to be aware of to ensure the efficient and correct operation of your
appliance. Please read on….
17 B DAILY CARE
To keep the surfaces of your appliance bright and clean, a daily wipe over with a lint free cloth is all that is
needed. A wet cloth may be used on certain surfaces.
To buff the cleaned surfaces, a soft, dry, lint free cloth should be used.
In order to keep your appliance in tip top condition, it is necessary to wipe up any spills or condensation streaks
as soon as is safe to do so. (i.e. when the unit is cold)
This will prevent the mark burning onto the appliance and becoming a much tougher stain to remove at a later
date, or causing a permanent mark. Try not to use excessive amounts of water when cleaning the appliance.
17 C CAST IRON
This can be cleaned with a lint free damp cloth. Do not leave this surface wet as it will go rusty. If it is cleaned
when the appliance is slightly warm, the damp surface will dry by itself. Otherwise, wipe the surface dry after
cleaning. Another method is to brush the surface with a soft brush. This is good for cleaning in the more detailed
and difficult to get to areas. If cast iron is left for long periods in a damp atmosphere; such as a fireplace; it may
start to show signs of rust. To prevent this, wipe the surface over with light oil. This will burn off when the fire is re-
lit.
17 D ENAMELED SURFACE
These can also be cleaned with lint free damp cloth and then wiped over with a dry cloth.
17 E GLASS CLEANING
Only clean the glass when the appliance is cold. There are various glass cleaners you can buy at stove shops
that are specially designed to remove hydrocarbon (soot) and fly ash (mineral) deposits from the glass. Follow the

© 2008-2009 Broseley Fires Ltd
manufacturer’s instructions. Alternatively use a proprietary ceramic hob cleaner such as Hob-brite, as used for
ceramic hobs. Follow the directions on the product.
17 F BROKEN GLASS
The glass in the fire door is ceramic and is resistant to sudden temperature changes up to 750 degrees
Centigrade. Breakage can only be caused by mechanical shock (collision, violent damage etc) because of this,
replacement is not covered by the guarantee.
17 G ASH REMOVAL:
The efficient operation of your appliance is dependant on its correct installation, operation and maintenance.
Leaving soot to accumulate inside your appliance will drastically reduce the output of the appliance and prevent it
from doing what it is designed to. Ensure that the ash inside every part of the appliance is removed, not just the
ash pan. Ash will settle on top of the baffle and this is an area that will also need periodic inspection.
17 H FLUE MAINTENANCE:
Call a certified chimney sweep (National Association of Chimney Sweeps) or other qualified professional to clean
the flue system. These professionals have the equipment and the experience to do a thorough job. The sweep will
advise you as to the intervals that you should have your flue swept. We would recommend that you have it swept
at least twice a year, but you may need to sweep it more.
Get them to inspect the condition of all the associated chimney items and report to you on their condition.
17 I ROPE SEALS:
For the appliance to operate correctly, it is important that all the seals; where fitted; are in good condition and are
sealing correctly. They should be replaced if they are showing excessive signs of fraying and are not making a
good seal. They are glued into position using a high temperature, flexible, silicone sealant
17 J AIR CONTROL:
Ensure that the air control operates smoothly and is free from ash or other foreign bodies.
18 SPARES
THE APPARATUS MUST NOT BE MODIFIED. ONLY SPARE PARTS EXPRESSLY AUTHORISED AND SOLD
BY BROSELEY FIRES LTD.
CONSULT YOUR LOCAL AUTHORISED DEALER FOR ADVICE.
Please refer to the drawings at the end of these instructions.