Cast Tec COUGAR 5 User manual

COUGAR 5
Multi-fuelstove
Ref. No. T1202 v 1 (22.4.14)
Installation and Operating Instructions
The Cougar 5 stove must be installed by a suitably qualified engineer.
Instructions must be given to the stove user when installation is complete
The installer must instruct user the correct use of the appliance and control operation
The Cougar 5 is manufactured to EN13240:2004 for Arbeia Trading Limited,
a Division of: Cast Tec Ltd., East Side, Tyne Dock, South Shields NE33 5SP
Website: www.casttec.co.uk Tel. [phone]

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Contents
THE CLEAN AIR ACT 1993 AND SMOKE CONTROL AREAS..............................3
INSTALLATION ESSENTIALS ..........................................................................3
PRE-INSTALLATION CHECKS & GENERAL SAFETY .........................................4
1. TECHNICAL DATA....................................................................................5
2. INSTALLATION.........................................................................................5
2.1 Installation responsibility ................................................................................................................................ 5
2.2 Unpacking the stove......................................................................................................................................... 5
2.4 Stove positioning & clearances......................................................................................................................... 6
2.5 The Chimney ..................................................................................................................................................... 9
2.6 Pipe connections ............................................................................................................................................. 9
2.7 Connecting to a masonry chimney ................................................................................................................. 10
2.8 Connecting to a steel chimney........................................................................................................................ 10
2.9 Draft conditions ............................................................................................................................................ 11
2.9.1 Commissioning & Handing Over............................................................................................................ 12
3. USER MANUAL .......................................................................................13
3.1 Choice of fuel .................................................................................................................................................. 13
3.2 Use .................................................................................................................................................................. 14
3.2.1 Use with wood....................................................................................................................................... 15
3.2.2 Use with solid fuel ................................................................................................................................. 16
3.2.3 Ash removal: (see Figure 5)................................................................................................................... 18
3.3 Maintenance ................................................................................................................................................. 18
3.3.1 Cleaning glass ....................................................................................................................................... 18
3.3.2 External surface cleaning ...................................................................................................................... 19
3.4 Operational problems –troubleshooting ....................................................................................................... 20
3.5 Replacement Parts ........................................................................................................................................ 21
3.6 Cougar 5 Assembly ........................................................................................................................................ 24

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The Clean Air Act 1993 and Smoke Control Areas
The Cast Tec Cougar 4.7kW multi-fuel stove has been recommended for exemption from UK
smoke control areas when burning wood and when fitted with a permanent stop to prevent
closure of the secondary airwash control beyond the 25% open position. Also, the tertiary air
inlet below the stove must be in a permanently fixed open position.
Under the Clean Air Act local authorities may declare the whole or part of the district of the
authority to be a smoke control area. It is an offence to emit smoke from a chimney of a
building, from a furnace or from a fixed boiler if located in a designated smoke control area. It
is also an offence to acquire an “unauthorised fuel” for use within a smoke control area unless
it is used in an “exempt appliance (“exempted” from the controls which generally apply in the
smoke control area)
The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to
authorise smokeless fuels or exempt appliances for use in smoke control areas in England. In
Scotland and Wales this power rests with Ministers in the devolved administrations for those
countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981, applies in
Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke
control areas have been "authorised" in Regulations and that appliances used to burn solid
fuel in those areas (other than "authorised" fuels) have been exempted by an Order made and
signed by the Secretary of State or Minister in the devolved administrations.
Further information on the requirements of the Clean Air Act can be found here:
http://smokecontrol.defra.gov.uk/
Your local authority is responsible for implementing the Clean Air Act 1993 including
designation and supervision of smoke control areas and you can contact them for details of
Clean Air Act requirements.
Installation Essentials
The installation of a fireplace or stove must be in accordance with local codes and regulations,
whilst also observing national rules and regulations in each country and other national and
European standards that apply.
Your Cougar stove must be installed by a Competent Person registered with a Government
Approved Competent Persons Scheme.
In the UK, HETAS is a qualified body that can assist with general advice, regulation,
installation, type of fuel usage and can provide a list of registered Competent Persons:
website is www.hetas.co.uk

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Pre-installation Checks & General Safety
If you are opening up an old or boarded up chimney or flue please be wary that asbestos
(a light grey coloured fire proof board) was often used to seal up or provide a vent into the
flue. This material can be dangerous and needs to be handled with care so seek
professional advice. Your local council should be consulted about means of disposal.
Ensure that any damper flaps or flue restrictors are fully removed from the flue.
Ensure that the flue in which the stove is fitted is not being shared by any other appliance.
Ensure that extractor fans are not fitted in the room in which the stove is to be installed.
The installer must ensure that the chimney flue is examined and tested for sturdiness and
suitability prior to installation. Any remedial work that is necessary should be carried out by
a competent person before the stove is fitted.
Your Cougar stove weighs 99kgs so please ensure that adequate precautions are taken to
receive delivery, move and position the stove prior to installation.
Ensure that an approved Carbon Monoxide Alarm is fitted into the room in which the
stove is installed.
Although additional ventilation is not normally required in the room in which the stove is
fitted, the installer must ensure that there is an adequate air supply and that if the room is
particularly or unusually airtight should refer to Document J of the Building Regulations for
clarification.
Ensure that your chimney is swept at least twice a year by a qualified or competent
chimney sweep if your stove is being used on a regular basis.
Ensure that your stove is well maintained by a competent engineer throughout its life so
that it runs safely and efficiently.
Ensure that you do not use aerosol sprays or any other combustible materials near to the
stove when it is in operation or for some hours afterwards.
Ensure that you read the instructions of stove care products such as rope seals and glue,
fire cement and paint finishes so that they are applied correctly and safely.
Your stove will become extremely hot during and after use so precautions should be taken
to ensure the safety of yourself and others (an approved fireguard for example) and in
particular for children, the elderly and the infirm who should be supervised at all times.

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1. Technical Data
Material: Cast-iron
Finish: High temperature resistant paint
Fuel: Multi-fuel (approved wood & smokeless fuels)
Log length: 34cm Maximum
Stove Outlets: Top and Rear
Flue Collar Size: 125mm (113cm2 cross section)
Approx. Weight: 99kgs
Distance Specifications: See Figure 2
Technical data according to EN 13240:2001
Wood
Smokeless Fuels
Nominal heat output
4.7kW
4.3kW
Flue gas mass flow
5.3 g/sec
4.1 g/sec
Recommended chimney draught
12Pa
Efficiency
74.7%
77.4%
CO emission (13% O2)
0.19%
0.24%
Flue gas temperature
271.3ºC
267ºC
Operational mode
Intermittent*
* Intermittent combustion in this context means normal use of the fireplace, i.e. fuel is added
as soon as the fuel has burnt down to embers.
2. Installation
2.1 Installation responsibility
Stove, fireplace and chimney installations MUST comply with all current National and Local
Building Regulations; your approved dealer or your local building control officer can advise
you regarding this. Ultimately, it is you and your installer who is responsible that the
installation complies with all the relevant rules, regulations and safety requirements for your
area at the time of installation.
2.2 Unpacking the stove
After removing the outer packaging, unbolt the combustion chamber from the wooden pallet
and place it gently on its back. The cardboard packaging can be placed underneath to prevent
marring. Remove the leg pack from the stove and bolt each leg securely to the underside of
the base on the combustion chamber, using the bolts provided (found inside the stove). We
recommend that two people perform the assembly and installation procedure.

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2.3 Tertiary Air Assembly
The assembly of the tertiary air control is shown in figure 1. This will be fixed in a permanent open
position as it allows airflow to be pre-heated to mix with exhaust gases allowing the exhaust gas to re-
ignite producing a cleaner and more efficient stove.
2.4 Stove positioning & clearances
The stove must be installed on a level surface with adequate load-bearing capacity. If an
existing construction does not meet this requirement then suitable measures such as a load
distribution plate must to be taken to achieve it.
Wooden floor protection
The stove can be placed directly on to a wooden floor that is covered by a metal plate or other
suitable, non-inflammable material. The recommended minimum thickness is 12 mm.
Any flooring made of combustible materials such as linoleum; carpets, etc. must be
removed from under the floor plate. Requirement for protecting combustible flooring
in front of, to the sides and rear of the stove must be in accordance with national laws
and regulations including BS 8303 and BS EN 15287-1-2007. See figure 2
Contact your local building authority regarding restrictions and installation requirements.

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Walls protection - Distance to wall made of combustible material
The stove can be situated next to a flammable wall using the minimum distance clearances
shown in figure 2 but also refer to Building Regulations BS 8303 and BS EN 15287-1 and any
other rules and codes that may be applicable.
Walls protection - Distance to wall covered by a firewall
The stove can be situated next to a firewall* wall using the minimum distance clearances
shown in figure 2 but also refer to Building Regulations BS 8303 and BS EN 15287-1 and any
other rules and codes that may be applicable.
*The firewall itself must be at least 100mm thick and be made of brick, concrete or stone.
Other materials and structures with satisfactory documentation may be used.
In exceptionable circumstances where only non-combustible walls surround the stove with
a minimum thickness of 200mm the clearance between the rear and sides of the stove may
be reduced to 50mm but this may effect efficiency levels which are based on the clearance
figures shown in figure 2 and reference should be made to building regulations and any rules
in force at the time of installation.
Ceiling protection
There must be a minimum distance of 1200 mm to a combustible ceiling above the fireplace.
Clearances to furniture and soft furnishings
We recommend that the stove be installed a minimum of 1000mm from furniture and other
combustible materials to the front of the stove. Serious consideration should also be given to
positioning of any furniture that could be adversely affected by heat. The clearances to
combustible materials in front of the stove should therefore be a minimum of 1000mm but the
further away the better.
Protecting Children and the Infirm
When lit, a wood-burning stove becomes extremely hot and therefore adequate protection
must be provided, particularly in situations where there is a safety risk to children or the infirm.
Vulnerable persons should be supervised at all times and a suitable safety guard or fireguard
manufactured in accordance with BS 8423-2002 should be considered. Remember, a stove
can also remain hot for some hours after the fire has ceased burning.

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Figure 2
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2.5 The Chimney
This Stove must never be connected to any shared chimney.
An efficient modern stove places heavy demands upon a chimney. You should have your
chimney regularly swept and inspected by an approved chimney sweep.
The cross-sectional area of the chimney (at its narrowest point) must comply with National
and Local Building Regulations. Generally, the area needed for a wood-burning stove
installation should measure at least 113cm2 (125mm diameter).
An over-sized chimney is generally hard to keep warm and results in poor draft. In cases here
there is an oversized masonry chimney, it is recommended that the chimney be lined using an
appropriate chimney lining system with the correct internal diameter.
With respect to the chimney termination, all chimneys should terminate in accordance with
National and Local Building Regulations.
Note that National and Local Regulations also apply with regard to the placement of chimneys
and flues in connection with thatched roofs.
The chimney or flue system must be equipped with access doors for inspection and cleaning.
The size of the cleaning door in the chimney must at least equal to that of the cross-sectional
area of the chimney. In the event that a chimney fire occurs resulting from faulty operation or
prolonged use of damp wood fuel, close the air vents completely and contact your local fire
department immediately.
2.6 Pipe connections
The stove is supplied with a 125mm diameter flue outlet collar to which a suitable rigid metal
flue pipe can be attached (not supplied). This must be of an approved thickness.
The flue outlet collar for this product is inside the burn chamber during transportation.
You can choose between a top or rear position for the flue outlet collar. There are three
screws provided for fastening the flue collar to the desired outlet. The outlet not being used is
closed off with a blanking plate with fixings that are provided. See figure 3.
Note! It is important that the joints are completely sealed. Air leakage etc. may lead to
malfunction.

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Blanking
Flue Outlet Collar
2.7 Connecting to a masonry chimney
A wall sleeve should be bricked securely into the wall of the chimney at the appropriate height
and the stovepipe inserted centrally. The pipe must not extend into the actual chimney
opening, but rather must reach only to the inside of the chimney aperture. The gap between
the stove pipe and sleeve must be sealed using glass fibre packing rope.
2.8 Connecting to a steel chimney
If your installation involves taking the chimney straight up and through the ceiling, you must
comply with National, Local Building Regulations or flue manufacturers instructions
concerning clearances to combustible materials such as walls, floor joists and ceilings. The
joint between the stove flue collar and the stove pipe must also be sealed using the glass fibre
rope provided. It is important that the insulated flue system is properly supported both at
ceiling level and at roof level.
THE STOVE MUST NOT BEAR THE WEIGHT OF THE CHIMNEY SYSTEM.
(See chimney manufacturer’s instructions). Excessive weight on the stove will inhibit
expansion and could lead to damage of the stove top. Damage caused to the stove in this way
would not be covered by the manufacturers guarantee.