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  9. Burley G4121 mk2 Assembly Instructions

Burley G4121 mk2 Assembly Instructions

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BURLEY G4121
mk2
FLUELESS GAS HEATER
INSTALLATION, SERVICING
& USER INSTRUCTIONS
FOR USE IN THE COUNTRIES STATED ON THE DATA PLATE AND CARTON
WITH NATURAL GAS G20
OR LPG PROPANE GAS G31
(REFER TO RATING LABEL)
For the fo owing countries: GB, IE
EVEN IF YOU HAVE FITTED THESE FIRES BEFORE,
PLEASE FOLLOW THESE INSTRUCTIONS STEP BY STEP.
Legislation and regulations do change over time!
LEAVE THESE INSTRUCTIONS WITH THE USER
Bur ey App iances Ltd,
Lands End Way, Oa ham, Rutland, LE15 6RB
Telephone: +44 (0)1572 756956 Fax: +44 (0)1572 724390
e-mail: info@burley.co.u web: www.burley.co.u
G4121InstUser
G20/31
Issue JAN08 – v.1
TO OBTAIN YOUR FIRST YEAR GUARANTEE, THE INSTALLER AND CUSTOMER
MUST FILL IN THE SEPARATE GUARANTEE AND RETURN IT TO
BURLEY WITIHIN 7 DAYS OF FITTING.
A FREE SECOND YEAR GUARANTEE IS OFFERED SUBJECT TO THE FIRE BEING SERVICED
BY A CORGI ENGINEER DURING THE FIRST YEAR OF OWNERSHIP.
PROOF OF SERVICING MUST BE RETAINED
FAILURE TO HAVE THIS APPLIANCE FITTED BY A CORGI REGISTERED
FITTER
INVALIDATES THE WARRANTY
2
INTRODUCTION
Than you for choosing this burley product. All of our products carry a CE mar which is awarded by
an independent test house (notified body) and shows the fires have been type tested to meet the
essential requirements of the European Gas Appliance Directive and the appropriate British
Standards.
This is a highly efficient Flueless Inset Live Fuel Effect Appliance. The burner system is very clean
burning and a catalyst cleans the combustion products even further.
A thermostat in the burner control system adjusts heat output to maintain a room temperature,
which can easily be set by the user. The appliance is operated via a battery powered remote control
system. There is also a separate control to adjust the flame effect as required. Please demonstrate
its operation to the customer before leaving.
An oxygen depletion sensing pilot light is also fitted and will sense any significant oxygen depletion
in the room and shut the fire down safely.
1. APPLIANCE DATA
Refer to the appliance data badge (affixed behind controls door) ENSURE THAT THE LOCAL
CONDITIONS OF USE CORRESPOND TO THE INFORMATION ON THE DATA BADGE.
Natura Gas G20 LPG (Propane) G31
Category I2H I3P
Supp y Pressure 20mBar 37mBar
In et Pressure 20mBar* 37mBar*
Burner Pressure (High) 9.4mBar 35.5mBar
(Low) 2.2mBar 8mBar
Heat Input (Net) (High) 3.5 W 3.5 W (250g/h)
(Low) 1.7 W 1.7 W (120g/h)
In et Connection 8mm Compression 8mm Compression
Injector stereo 185 stereo 95
*The inlet pressure must be within +/- 1mBar of specification with a gas appliances in the house
switched on and a so with just the Burley heater operating. If outside of this tolerance the fault is
most li ely to be in the installation pipe wor or service governor at the meter. If the problem is the
meter governor, this is the property of the gas service provider (such as Transco / National Grid
0800 111999 or Bord Gais) and they should be called to rectify this. The fire will not operate
correctly if the pressures are incorrect.
2. UNPACKING THE APPLIANCE
2.1 Carefully examine the carton for damage before unpac ing. If it is obviously damaged,
consult the supplier as to whether to proceed with the installation.
2.2 Ma e sure the carton is stood upright and open the top. Remove the cardboard top fitting
and place to one side; this box can be used as a hearth protector when installing the fire.
2.3 Remove the fittings boxes contained within and open them and chec the condition of the
contents. Remove the fire and examine its general condition, paying particular attention to
the frame, the glass front and fire box flanges.
2.4 If satisfied by the general condition, place the decorative components to one side and
proceed with the installation. If in any doubt, see advice from the supplier. Read these
instructions fu y before proceeding even if you have fitted this mode before.
3
3. GENERAL REQUIREMENTS
3.1 Gas appliances must be installed in accordance with the rules in force. In the UK it is the law
that all gas appliances must be installed by a CORGI registered installer, in accordance with
the Gas Safety (Installation and Use) regulations (as amended). The installation must also be
in accordance with the relevant parts of local and national building regulations and in
accordance with BS5871 pt4 except where Burley instruction state differently. For the
Republic of Ireland, reference should be made to IS813 and ICP3 and any guidance notes
from Bord Gais. Failure to have the fire fitted by a qualified person nullifies ALL guarantees.
3.2 The space to be heated must have a wall vent of at least 100cm² of ventilation and an
openable window or patio door. The vent must be positioned at least 1 metre away from
the appliance. A vent may have been supplied with the appliance and this is the preferred
type although it is possible to use alternatives.
3.3 In the Republic of Ireland two vents of not less than 60cm² each, one not less than 1.6m
above the other, must be installed in the room.
3.4 When providing ventilator openings consideration must be given to the avoidance of
locations where discomfort from draughts may cause the user to bloc the openings.
Similarly the possibility of curtains or furniture bloc ing ventilation openings must be
considered. Floor vents, closable window vents or chimneys are not suitable means of
ventilation.
3.5 Wor ing surfaces include the air outlet grille.
3.6 The heater must not be used in a room area of less than 40m3 in volume. To convert cubic
feet (ft³) to cubic metre (m³) divide the room volume in cubic feet by 35.3. Adjoining spaces,
not separated by a door may be combined.
3.7 The heater must not be used on or against a combustible surface.
3.8 No furniture, soft furnishings, decorations, wall coverings or curtains must be within 1 metre
of the appliance and its convection outlets.
3.9 The heater must not be installed in high rise flats or basements.
3.10 Do not install this appliance in:
a) A bathroom, shower room or in a room used or intended to be used as sleeping
accommodation. Sleeping areas must be separated from the appliance by a door.
b) In a cupboard or compartment within such a room; or
c) In a cupboard, compartment or space adjacent to such a room if there is an air vent from
the cupboard, compartment or space into such a room.
3.11 When the heater is not to be used for a time, ensure the gas control or adjacent isolators
are turned off.
3.12 Using this appliance as a sole heat source can lead to condensation problems in periods of
cold weather and heavy use. Always ensure that the room has a bac ground heat source
such as central heating or storage heaters.
3.13 The fire must not be run with its door open or with crac ed, incorrectly fitted or missing
glass.
3.14 The glass door acts as a guard on the appliance to prevent ris of fire or injury from burns
and no part of it may be permanently removed. It does not give full protection for young
children, the elderly or infirm. Parts of the appliance get hot, an additional guard to BS6539
or BS6778 must be used in the presence of children, the elderly and infirm.
3.15 This is not a drying appliance. Do not place clothing or other articles, on or against it.
3.16 On no account must air inlets under the stove or outlet grills (see diagram below) be
obstructed.
3.17 Do not store or use flammable substances on or near the heater.
3.18 Do not spray aerosols on or near the heater when it is wor ing.
4
3.19 Do not use whilst painting & decorating, or in newly decorated rooms as the residues can
lead to unpleasant smells from the appliance. Always cover or have the appliance removed
when decorating.
3.20 The heater must not be used in rooms where the atmosphere is li ely to contain water or
chemical vapours which may adversely affect the appliance or its finish.
3.21 If any material, such as plastic, melts onto the surface of the glass, turn the heater off and
a ow it to coo . Do not remove the materia when hot. A proprietary ceramic hob cleaner
such as ‘hob brite’ can be used to clean the glass. Only clean the appliance when cold.
4. WARNINGS
4.1 Read the instructions before using this app iance.
4.2 This app iance requires insta ation by a competent qua ified person.
4.3 Use on y in a correct y sized and venti ated area.
4.4 Once the coa s have been positioned in accordance with the insta ation instructions, they
must not be moved except for servicing.
4.5 The surfaces of the app iance become very hot during use.
4.6 Before c eaning or maintenance switch fire OFF and a ow to coo .
4.7 Any purpose provided venti ation shou d be checked regu ar y to ensure it is free from
obstruction.
Overa Dimensions
5. Hearths, f oor protection and carpets
5.1 This appliance does not need a hearth and can be used on wooden, laminate floors and non-
combustible surfaces. It must not be placed directly onto carpets or rugs. Where the floor is
carpeted, the carpet must finish 100mm clear of the appliance legs and be fully removed
underneath. Loose rugs should be ept well away from the appliance (warn the customer of this).
5.2 Standing the appliance directly on a floor can lead to discolouration and / or drying out.
5.3 When a hearth is used, the top surface can be wood but be aware that heat can discolour certain
finishes over a period of time and can dry out poorly seasoned wood causing splitting. The hearth
should be 100mm larger than the appliance all round and minimum 12mm thic . Carpets can come
to the edge of the hearth.
540
620
330
Outlet grille
DO NOT COVER
Air inlets
DO NOT BLOCK
5
6. C earance to Wa s
Rear C earance - The rear of the appliance can be installed directly against a non combustible wall. A
distance of 50mm should be allowed to walls with wooden cladding, wallpaper, or finishes li ely to be
affected by heat.
Side C earance - The sides of the appliance can be installed with 25mm of side clearance to non combustible
materials. Combustible material such as wood may be fitted to within 100mm of the sides of the firebox
provided it protrudes no further forward than 100mm.
Top C earance - The heat from the appliance is concentrated towards the front edge directly above the
combustion products outlet. The clearances stated relate to a distance from the bac edge of the stove.
A non combustible shelf may be fitted to within 50mm of the top edge of the fire.
Maximum depth of shelf 100mm 150mm 200mm
Minimum distance from 200mm 250mm 300mm
Top of fire to underside of shelf
These distances shou d be doub ed if the she f is above the out et gri e.
The firep ace and ALL materia s inc uding paints or acquers must be rated for a minimum
constant temperature of 150°C. Any hearth or back pane not meeting the above c earance
dimensions must be made from a non-combustib e materia such as marb e or s ate, a though
‘ ightweight’ and ti ed surrounds can be used provided they have a minimum heat rating of
150°C.
7. Gas Supp y
The gas supply should be installed in accordance with all regulations in force. Consideration should be given
to the routing to conceal from view and avoid potential damage. Pipes through walls should be sleeved. The
gas connection is 8mm compression and should be made in semi-rigid tubing such as copper pipe. Before
wor ing on pipewor plug open ends. A servicing isolator is supplied with the appliance and this should be
used to permit disconnection for servicing etc.
All gas wor should be underta en by a competent person, see General Requirements.
8. Siting the App iance
8.1 If the appliance is to be in or in front of an open fireplace, the chimney or flue MUST be bloc ed off
to prevent the draw from disrupting the flame pattern of the fire, which can lead to poor
combustion, or sooting. Extractor fans must be sited at least 2m from the appliance.
8.2 Chec the room has sufficient volume and ventilation, if these requirements cannot be met then the
appliance should not be installed. Consideration should be given to the requirements of other
appliances wor ing in the same room space. If other flueless appliances such as coo ers are in the
same room then consideration should be given to the combined room size requirement.
8.3 Chec the room has a bac ground heat source such as central heating radiators, storage heaters etc.
8.4 Chec the appliance data plate details are correct for the ind of gas used and the country of
installation.
8.5 Carry out any building wor s such as ingle-noo s, hearths and recesses. If no hearth is being used,
remove any carpets to required clearance. Lay in the gas supply and leave a tail to connect to.
8.6 Position the appliance and ensure it is stable and unli ely to move in normal use. Some hearths can
be slippery and it is best to fix the appliance by removing the plugs in the plastic feet and screwing
down. Care should be ta en to ensure correct clearances around the stove.
8.7 Before connecting any pipes to the appliance, fully purge pipes of any debris or swarf etc.
8.8 Attach the gas connection to the stove and carry out a lea test in an approved manner.
8.9 Unclip the thermostat from the bac of the stove and by carefully extending the capillary tube locate
it in a place where it will sense room temperature. This is particularly important if the stove is fitted
in an ingle noo where the thermostat could give a misleading shut down unless it is relocated to a
cool location. We recommend clipping to the rear of the appliance.
6
9. Laying the Logs
Opening the hinged door on the appliance, which is secured by a 10mm nut, gains access to the coals. On no
account should the appliance be operated whilst the door is open except for brief periods during
maintenance. Do not lay the log in any way other than that shown.
LOG LAYOUT (NATURAL GAS)
The base and front logs are fixed in position and
should only need removing for servicing. The base
log locates onto the burner and the front log is
pushed to the extreme left hand side. Ta e the 2
loose logs* and position them as shown onto the cut
outs on the base log, ta ing care to locate them
correctly to ensure clean combustion. No additional
logs should be added to the fire.
Note the pilot position on the right hand side of the
burner.
LOG LAYOUT (LPG PROPANE)
The base and front logs are fitted similar to the
Natural Gas fire. The base log locates onto the
burner and the front log is pushed to the extreme
left hand side as shown. Ta e the 2 loose logs* and
position them as shown onto the cut outs on the
base log, ta ing care to locate them correctly to
ensure clean combustion. No additional logs should
be added to the fire.
Note the pilot position on the right hand side of the
burner.
*Note – The 2 top ogs may be supp ied g ued in
position and shou d not be removed or repositioned. If they become detached then they can be fitted as
per the diagram but must on no account be discarded or fitted in any other way.
A ways secure the door c osed after aying the fue effects.
Do not attempt to use any unit with broken or damaged g ass.
Do not use the fire with broken ogs.
Do not add any additiona fue e ements to the fire.
Do not use simi ar ooking parts from other app iances, use on y genuine spare parts.
Do not use the app iance for burning waste.
10. Commissioning the App iance
If the pipes have not been purged of debris do it before ighting the app iance. Fai ure to do so wi resu t
in b ockages within the burner and pi ot.
7
M
H
L
Control Knob
Thermostat
Bur ey App iances is the on y company to bench run and thorough y test every sing e gas fire it produces.
Bur ey is in the unique position of knowing that every app iance that eaves the factory is in perfect
working order.
The installer should measure the inlet pressure with the appliance running on high and ensure it is to
specification.
Attach a manometer to the inlet test point and ensure there is a pressure of 20mb (+/- 1mb) for natural gas
appliances or 37mB for propane appliances.
Now turn on every other gas appliance in the house and re-chec the pressure. The pressure must still be
within the tolerance of +/- 1mb.
Turn off all other gas appliances and turn the fire down to pilot only, the pressure must still be within the
tolerance of +/- 1mb.
If it is not TRANSCO or BORD GAIS must be called to adjust the regulator to the house before the fire can be
commissioned further.
Any large pressure fluctuation indicates pipewor or governor problems and should be rectified. Instruct the
customer on the operation of the appliance and leave all instructions with them.
The fires are factory set and no adjustments should be made in the field.
11. Lighting the Heater
To light the fire, press the left hand (red) control nob for
several seconds then turn anticloc wise to the ignition
position. A clic will be heard and the pilot (under right side
of fuel bed) should light. If it does not light, repeat the
operation a few times. Continue to hold nob for 15 – 20
sec's to establish the pilot and then release. If pilot fails to
establish, turn off, wait 1 minute then repeat lighting
procedure. Rotate the control nob to high flame to light
then bac to the desired flame position. If no gas comes
through rotate the right nob (thermostat) to a hotter room
setting and the fire will light. To turn the fire off, rotate nob fully cloc wise.
12. Spark Fai ure
The gap between the pilot electrode and the pilot should be 3.5 – 4.5mm and normally adjustment is not
necessary. Chec the fire lights at least 3 times out of 5 attempts. Visually chec that the spar arcs across to
the gas port on the pilot. The electrode is delicate but if necessary can be adjusted to set the spar . If the
igniter fails a lighted taper can be inserted into the pilot area when attempting to light the pilot and this
should help the fire to light.
13. Thermostat
A room temperature thermostat is attached to the bac of the fire. For accurate monitoring of room
temperature it is advised that the sensing bulb is removed from its clip and carefully moved to a cooler
location up to 1 metre away, ta ing care not to brea or pinch the capillary tube. If the fire is fitted in an
ingle noo then the thermostat should be located in room air as leaving it under the fire will cause nuisance
shut down.
14. Fireguards
The glass front on the appliance acts as a dress guard but does not provide full protection. An additional
guard should always be fitted in the presence of young children, the elderly or the infirm.
8
15. Oxygen Dep etion Pi ot System
There is a highly sensitive oxygen depletion sensor designed into the pilot light. If any part is damaged the
entire unit must be replaced using only genuine spare parts as similar loo ing parts from other appliances
may well give inferior performance. If the fire repeatedly trips off in operation the oxygen depletion system
may be operating and a qualified engineer should investigate this.
16. Instructing the Customer
The installer should instruct the customer on the operation of the appliance and handover all instruction
leaflets.
The customer must be made aware of the need for regu ar servicing of the app iance, this wi norma y be
once a year.
The customer should also be made aware that no rubbish should be thrown into the firebed and that
purpose provided ventilation should be chec ed regularly.
17. Servicing Instructions
Before commencing any servicing, ensure that the gas is iso ated and the app iance is coo .
Cleaning – The casing should be wiped with a cloth dampened in soapy water. The glass may be cleaned
with any non-abrasive cleaner such as ‘hob brite‘.
The coals contain refractory fibre (RCF). Excessive exposure to these materials may cause temporary
irritation to the eyes, s in and respiratory tract; consequently, it ma es sense to ta e care when handling
these parts to ensure that the release of dust is ept to a minimum. We recommend the use of a HEPA
filtered vacuum to remove any dust and soot accumulated in the heater before and after wor ing on it.
When replacing these articles, they should not be bro en up, but sealed in heavy duty polythene bags
labelled RCF Waste’, which may be disposed of at a tipping site licensed for industrial waste. Protective
clothing is not required, but normal hygiene rules of no smo ing, eating or drin ing in the wor area should
be followed.
Controls – The system for monitoring the oxygen supply to the burner is not adjustable and must not be put
out of operation. Should the oxypilot system need to be replaced, the original manufacturer’s parts must be
used.
Injectors – Only origina manufacturer’s injectors must be used.
The unit must be serviced at least once per year, preferably at the beginning of the heating season. All
servicing must be carried out by a qualified service person. A combustion analysis chec should be carried
out using an analyser to BS7967 and sampling the entire width of the combustion product outlet. Ratio of
CO/CO2 should be less than 0.002 within 30 minutes. (20ppm CO per 1% CO2) A reading of CO in the room
centre should give a rise of less than 9ppm over ambient, pea reading.
Light the fire using the method in the instructions and ensure that the pilot lights consistently and the pilot
flame envelopes the thermocouple evenly, it is located at the front on the right-hand side.
The pilot should hold in 6-10 seconds. Turn control to main burner, this should light smoothly within 10
seconds. Ensure the valve gives adequate turn down and the thermostat bulb reduces the burner rate to off
when heated.
Locate thermostat bulb in a cool place off the appliance and preferably outside of any inglenoo s, to ensure
it is sensing room air temperature.
Run the appliance for 10 minutes, ensuring burner flames settle evenly.
The gas manifold pressures are factory pre-set using highly accurate equipment, and must not be altered.
The catalyst is unli ely to need replacement during the life of the heater. The appliance should be inspected
before use and at least annually by an authorised service person. More frequent cleaning may be required
due to accumulation of lint and dust from carpeting etc.
9
It is imperative that the control compartments, burners and circulating air passageways of the appliance be
ept clean. Replacement parts are available from your local dealer.
18. Accessories
Using unapproved accessories could prove hazardous and wi invalidate the warranty.
BURLEY APPLIANCES ARE THE ONLY COMPANY TO BENCH RUN AND THOROUGHLY TEST EVERY
SINGLE GAS FIRE IT PRODUCES. BURLEY ARE IN THE UNIQUE POSITION OF KNOWING THAT EVERY
APPLIANCE LEAVES THE FACTORY IN PERFECT WORKING ORDER.
Due to our po icy of continua improvement and deve opment the exact accuracy of descriptions
and i ustrations cannot be guaranteed.
Due to our policy of continual improvement and development the exact accuracy of descriptions and illustrations can
not be guaranteed.
Burley Appliances are the only company to bench run and thoroughly test every single Flueless gas fire it produces.
Burley is in the unique position of kno ing that every appliance leaves the factory in perfect orking order.
10
User Instructions
WARNINGS
1. Read the instructions before using this app iance.
2. This app iance requires insta ation and annua servicing by a CORGI registered insta er.
3. Use on y in a correct y sized and venti ated area.
4. Any purpose provided venti ation shou d be checked regu ar y to ensure it is free from
obstruction.
5. Once the ogs have been positioned in accordance with the insta ation instructions; they must
not be moved except for servicing.
6. The surfaces of the app iance become very hot during use.
7. If necessary the casing shou d be wiped with a c oth dampened in soapy water. Do not attempt
to touch or wipe the fire whi st it is hot, doing so cou d resu t in damage to the paint finish and
severe burns. Do not use any chemica c eaning agents or abrasive c eaners to c ean the paint
work of the fire as this may resu t in damage not covered by the guarantee. If the paint becomes
damaged or worn, specia touch up paint is avai ab e from our service department on 01572
756956. Do not use any other type of paint.
GENERAL REQUIREMENTS
1. The heater is intended as a secondary heat source. Chec that a primary source of heat (such as
radiators) is present in the room. If insufficient primary heat is being used there may be a build up
of condensation.
2. The heater must not be used on or against a combustible surface. No furniture or curtains must
be close to the appliance (or at ris of being blown close)
3. In the event of gas lea age, the gas supply must be turned off and advice sought.
4. The guard on the appliance is to prevent ris of fire or injury from burns and no part of it may be
permanently
removed. It does not give full protection for young children, the elderly or infirm. Parts of the
appliance get hot,
it is strongly recommended that an additional guard to BS6539 or BS6778 is used in the presence of
children
the elderly or infirm.
5. This is not a drying appliance. Do not place clothing or other articles, on or against it.
6. Do not store or use flammable substances on or near the heater.
7. Do not spray aerosols on or near the heater.
8. If any material, such as plastic, melts on the surface of the glass, turn the heater off and allow it
cool. Do not remove the