Chilli Penguin Chilli Billie User manual

www.chillipenguin.co.uk
CSP 9768 11/2020
Installation and Operating Manual
The Chilli Billie
Sales and Technical Support
Call: 01758 721 247
sto[email protected]o.uk
Local Stockists
www.chillipenguin/contact
Chilli Penguin Workshop
11 Glan y Don Industrial Estate | Pwllheli | Gwynedd LL53 5YT.
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The little stove
with a big heart
The Chilli Billie
(Wood only)
(Stôf Fach Gyda Chalon Fawr)

We recommend the goldilocks and the three bears method;
small fire, medium fire, hot fire.
Simple guide to your first fire
read this manual and a warnings carefuy
The A, B & C of lighting your 1st stove fire are:
A = air control B = burn dry wood C = cure paint carefully
prepare a sma kindling fire
• scrunch up paper/firelighter, place under kindling in a teepee shape inside the firebox.
• arrange paper so it is accessible via front lighting hole, close lid.
• open all air controls: primary, secondary, lighting hole and ash pan door
• light a match, long ones are easier and light the paper through the lighting hole
• burn for 15 minutes
medium fire
• once the kindling fire is well established add larger split logs, use gloves
• close ash door and adjust controls
• burn for about an hour
hot fire
• add additional wood
• burn for an additional hour
• your stove paint should be largely cured!
Page 01 of 43 www.chillipenguin.co.uk

Page 02 of 43
Important - read before first fire
The painted finish must be cured and set properly.
We use a high temperature stove paint on all of our stoves. It is extremely important
that the paint is cured properly the first time that you light the stove. This is done to
ensure the paint finish will be able to withstand the high temperatures needed. Curing
is done by following the three step process on the facing page. If this process is not
done properly you may experience issues with the paint peeling. We want your Penguin
to be perfect!
To Set / Cure the paint
Once this initial process has been completed, the paint will be properly cured and you
can operate your stove normally according to the instructions provided in this manual.
If any peeling of the paint occurs on your stove this will only be as a result of improper
curing or misuse of the stove such as over fuelling or running the stove too hot.
Therefore any peeling is not covered by your warranty.
Note: During the final higher temperature burn phase there may be some visible smoke
near the stove surface. There may also be an unpleasant odour. To mitigate this eect,
ventilate the room with open windows and doors to provide airflow.
Health warning: The smoke from the curing process displaces oxygen. Small children,
the elderly and people with existing breathing problems should vacate the area during
the hot burn to avoid discomfort. The smoke is primarily Carbon Dioxide, is non-toxic
but can feel uncomfortable.
you’ve bought an amazing stove,
let it be amazing

Page 03 of 43 www.chillipenguin.co.uk
Your chii biie should arrive with...
• A pair of heat resistant gloves
• A tool for operating the stove and removing the ash pan
• An instruction manual
• An ash pan
• An aerosol of spray paint - coloured stoves only
• A warm fuzzy feeling indicating that you are now a part of the penguin family
Chii biie enclosure package should arrive with...
• All of the above
• An enclosure
• A side shelf
• Starter pipe
We guarantee that your stove is good quality and well made.
We know this because we design and make them ourselves here in Wales.
We are convinced that stoves make the autumn fabulous and the winter sublime.
We hope that your stove will make the bad days bearable and the good days great.
We think that human beings with stoves are happier than those without.
We believe that your life has just got better.
The charter of the penguin

Contents
Simple guide to your first fire
The goldilocks and the three bears method
P. 01
Read before first fire
To Set / Cure the Paint
P. 02
Section 1
The Charter of the Penguin
Your Chilli Billie should arrive with...
Content
Penguin Series Summary
Introduction
P. 03
Section 2
The plans & technical details
P. 06
a)
b)
The Chilli Billie (not in enclosure)
The Chilli Billie (in enclosure)
Section 4
Instructions for use
P. 25
a)
b)
c)
d)
e)
f)
Diagram of Chilli Billie
Description of Chilli Billie
Warnings and Pre-lighting Checks
Simple Guide to your First Fire
Principles of Combustion
Instructions for use
Section 5
Maintenance
P. 32
a)
b)
c)
d)
e)
f)
g)
h)
Routine Checks and Cleaning
Painting your Stove or Stove Pipe
Keeping your Stove Glass Clear
Top Loading Door Seal & Ash Door
Glass Replacement
Vermiculite Bricks
To Remove the Throat Plate
Trouble Shooting
Section 6
Efficiency/CE labels & Guarantee
P. 40
a)
b)
c)
Energy Eciency and CE Labels
Guarantee
Commissioning, Stove and
Installation Details
Section 3
Installation instructions
P. 11
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
Domestic Installations (In Houses)
Installations (Glamping/Leisure
Accommodation)
Smoke Control Adaptation
Smoke Control Principles
Siting and Escape Routes - Domestic/
Glamping & Leisure
Ventilation - Domestic Installations
Ventilation - Glamping or Leisure
Accommodation
Floors - Domestic/Glamping & Leisure
Co Alarm and Smoke Alarm -
Domestic/Glamping & Leisure
Fireguard - Domestic/Glamping
& Leisure
Hearth (Domestic Installations)
Hearth (Glamping or Leisure
Accommodation)
Heat Shielding
Heat Shielding Flue
Installation Domestic Non Combustible
Builders’ Opening
Installation In Timber Structure No
Heat Protection
Installation In Timber Structure With
Enclosure
Installation Diagram Combustible Wall
with Heat Shield
Chimney Design Page 04 of 43

This manual is for the following stove in the Penguin Series.
Penguin series suary
Chilli Billie
Model
Output 3.4kW
Chilli Billie
Page 05 of 43 www.chillipenguin.co.uk
Introduction
Thank you for purchasing a Chilli Penguin Stove. You have purchased a quality product
that has been built to last, designed and manufactured in the UK.
We put a lot of time and energy into developing and improving our stoves to enable
them to run as eciently as possible and be simple to use. Please spend a few minutes
familiarising yourself with this manual, so you can get the best possible performance
out your stove.
We love to hear how the penguins get on in their new homes, if you have any
comments or questions, please get in touch or share a picture on social media.
If you have a quiet moment and want to make a penguin very happy, our penguins
love good reviews - Google, Facebook and Whatstove are a few most used for
good reviews.
www.chillipenguin.co.uk
This expanded Chilli Billie manual gives information that relates to the two
dierent types of installation
• Domestic (houses)
• Glamping and Leisure structure (eg. Shepherd’s huts, yurts, safari tent)
There are dierence between the two types, you will see this in the technical
details and in the installation instructions

The plans &
technical details
Page 06-10
Section 2
Page 06 of 43

405mm
105mm
531mm
504mm
229mm
321mm
75mm
The Chilli Billie (Stôf Fach Gyda Chalon Fawr)
2.a The Plans
The Plans (not in enclosure)
Page 07 of 43 www.chillipenguin.co.uk

The Chilli Billie (Stôf Fach Gyda Chalon Fawr)
2.a Tech Details
The Tech Details (not in enclosure)
Fuel Type Wood Only
Nominal Output 3.4kW
Total Energy Eciency % (wood/smokeless fuel) 80%
Distance To Combustibles Side 400mm Rear 400mm Above 400mm
Distance To Non Combustibles Side 100mm Rear 50mm Above 150mm
Optional Side Shelf Yes, need to specify right/left
Exemption Testing complete Yes
Can stove be adapted for SmokeControl area Yes
Max. Log length x average diameter 250mm x 80mm
Flue Aperture Diameter 105mm (105-125mm adaptor required, often sold as 4-5”adaptor)
Flue size required for stove without smoke control adaptation - domestic
Single skinned 125mm increasing to double skinned 150mm
Flue size required for stove without smoke control adaptation - glamping or leisure
Double skinned 125mm
Flue size required with smoke control adaptation - domestic / glamping or leisure
Single skinned 125mm Increasing to double skinned 125mm (minimum)
Flue Exit Top Only
Hearth type in house or structure with permanently fixed floor
12mm superimposed hearth, stove should be fixed to it, stove anchor plate available
Hearth type instructure without permanently fixed floor
Min 12mm, on levelground, stove should be fixed to it, (refer to hearth section), stove anchor plate available
Chimney draught required 12Pa
Construction Welded steel, painted finish
Nett weight 40kg
Flue gas g/s 2.8g/s
Mean flue gas temp 228°C
COcontent @13% oxygen 0.44%
Page 08 of 43

865mm
127mm
The Chilli Billie (Stôf Fach Gyda Chalon Fawr)
2.b The Plans
The Plans (in enclosure)
Page 09 of 43 www.chillipenguin.co.uk
650mm
130mm
685mm
685mm
225mm
Round Enclosure Plan View Square Enclosure Plan View
Integral
Support
Bracket

• The steel enclosure ensures a safe and secure housing for the stove, it maintains
safe distance to combustibles for the stove and single walled flue, if enclosure
distances are maintained. It maintains a separate and distinct visual area where the
fire occurs.
• It is open top and bottom to allow the free flow of cool air
• It is double skinned underneath the stove and around the full height of the stove
• Flue bracket provides stability for the flue without the need for wall brackets on
shorter flues
• Stove anchor plate available to attach stove to enclosure
• Optional side shelf available - right side standard
• Two types of enclosure available - round or square(ish)
• If you order the chilli billie package it will come with a section of chilli penguin
starter pipe, this goes from the top of the stove and into the integral support
bracket. The twin wall pipe for the rest of the installation must start at the bracket.
2.c Description of Penguin Enclosure
Page 10 of 43
The Chilli Billie
2.b Tech Details
The Tech Details (in enclosure - round or square)
Dimensions - Square Enclosure Height 865mm
Sides 685mm x 685mm
Distance from enclosure to combustible surface Side 100mm
Rear 50mm
Hearth type needed when in an enclosure
Enclosure acts as hearth in house
or structure with a permanent shell.
Other structures require a hearth
(refer to hearth section)
Max lengthof single walled flue in enclosure 300mm
Construction Welded steel, painted finish
5” diameter / 125mm Starter pipe with sweeping access door supplied with enclosure
Dimensions - Round Enclosure Height 865mm
Diameter 650mm

Instaation
instructions
Page 11-24
Section 3
Page 11 of 43 www.chillipenguin.co.uk

3. Installation Instructions
All local and national regulations must be observed when installing the appliance. If
installed incorrectly serious accidents can be caused.
BUILDING REGULATION REQUIREMENTS (DOMESTIC)
Building Regulation Document J must be refered to when installing this appliance.It is
the installers responsibility to ensure the manufacturers instructions are complied with.
A HETAS qualified installation engineer should carry out the installation and issue a
compliance certificate or alternatively your local Building control department needs to
inspect the installation and register the work carried out.
3.a Domestic Installations (In Houses) - Warning
There has been a growth in the use of woodburning stoves in glamping, leisure and
small space accommodation, such as shepherds huts, wooden pods, yurts and safari
tents. We recommend that you fit a Chilli Billie in any structure to the same standards
that you would in a house. The risks are the same, if not greater in a small space.
Combustible surfaces are likely to be closer, so it needs careful design consideration in
the planning stage.
We believe that there are additional risks in canvas structures e.g. yurts, teepees and
safari tents. Adverse weather can cause movement of the surface the flue is exiting
through. The surfaces of some structures e.g. a yurt may be flamable. The flashing must
allow for some movement and the stove, enclosure and each section of flue should be
mechanically fixed to each other and the hearth to prevent smoke spillage under these
circumstances.
We recommend that you be guided by the principle of taking all and every
reasonable precaution to protect and preserve safety. This is of particular importance
if these structures are used for holiday/event rental as the users can be unfamiliar
with wood burning stoves and any risks factors that a single, regular user might be
sensitive to.
3.b Installations (Glamping/Leisure Accommodation) - Warning
BUILDING REGULATION REQUIREMENTS (GLAMPING/LEISURE)
Although the regulatory requirements currently stipulate that leisure accommodation
units fall outside the remit of Schedule 2 of the UK Building Regulations, installers
should always ensure under their responsibilities as a competent engineer that
installations are done in a manner that is deemed safe, and meet the fundamental
safety and eciency requirements as laid out in regulations J1 to J5 of Approved
Document J where practical. Page 9 of ADJ sets the legal precedents as follows:
J1 Air Supply: Combustion appliances shall be so installed that there is an adequate
supply of air to them for combustion, to prevent overheating and for the ecient
working of the flue.
Page 12 of 43

The general principle to be observed in an Exempt Chilli Penguin stove, suitable for use
in smoke control zones, is that the air controls cannot be completely closed, allowing a
permenant air supply to the fire chamber. This means that fuel burns more eciently,
thereby emmiting less smoky emissions into the atmosphere.
“The Clean Air Act 1993 and Smoke Control Areas”
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 oence to emit smoke from a chimney
of a building, from a furnace or from any fixed boiler if located in a designated smoke
control area. It is also an oence 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 Aairs 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.
3.d Smoke Control Principles
If the accommodation is EITHER sited in a smoke control zone, OR has provision to be
transported or resited in a smoke control area the smoke control adaption should be
applied.
To make the Chilli Billie suitable to burn in a smoke control area, there is simple
adaptation. The secondary air control dial need to be removed. Make a note in this
manual if this has been done, on the commissioning page.
3.c Smoke Control Adaptation
J2 Discharge of Products: Combustion appliances shall have adequate provision for the
discharge of products of combustion to the outside air.
J3 Detection of CO: Where a fixed combustion appliance is provided, appropriate
provision shall be made to detect and give warning of the release of carbon monoxide
J4 Protection of Building: Combustion appliances and flue pipes shall be so installed
and fireplaces and chimneys shall be so constructed and installed as to reduce the
reasonable level the risk of people suering burns or the building catching fire in
consequence of their use.
J5 Provision of Information: Where a hearth, fireplace, flue or chimney is provided or
extended, a durable notice containing information on the performance capabilities of
the hearth, fireplace, flue or chimney shall be axed in a suitable place in the building
for the purpose of enabling combustion appliances to be safely installed.
Page 13 of 43 www.chillipenguin.co.uk

In addition to the above considerations we recommend an air vent in any small
sealed structure such a shepherds hut, garden shed/oce placed at both high or low
level. This is a provision for combustion air in small spaces and a carbon monoxide
precaution. It should be in a position that it cannot easily be blocked. Vents should be
positioned as close as possible to the stove, at least 300mm away from the chimney or
other flue outlet.
3.g Ventilation - Glamping or Leisure Accommodation
• In order for a stove to operate correctly there needs to be sucient combustion air
• For stoves of 5 kW and under such as the Chilli Billie a permanently open vent is
sometimes required, usually in new build houses and extensions. This can depend
on the air permeability (air leakage) of your property. Your HETAS installer should
be able to guide you.
• The general principle is 550mm2 of ventilation per kW output of stove.
• Confirmation of the amount of ventilation can be verified with a smoke spillage test.
• In addition a stove should not be fitted in a room with an appliance such as
extractor fan, ceiling fan or tumble drier, it will aect the draw of the stove and
could lead to fumes entering the room.
• All air vents should be positioned so that thay are not liable to blockage
3.f Ventilation - Domestic Installations
3.e Siting and Escape Routes - Domestic/Glamping & Leisure
The siting of your Chilli Billie must not be in a position that will block or inhibit exit from
the accommodation in an emergency. It must not increase the risk of ignition to the
fabric of the accommodation, whether domestic or leisure.
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:
www.gov.uk/smoke-control-area-rules
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.
The Chilli Billie with smoke control adaptation has been tested as suitable for use in
smoke control areas, it is awaiting certification.
Page 14 of 43

• The Chilli Billie can either sit in a penguin enclosure or on 12mm superimposed
hearth (a non combustible decorative hearth material e.g. slate/granite)
• The stove should be fixed to the enclosure or hearth
• The enclosure if used, should be fixed to the floor or hearth
• Combustable materials, including wood should not be stored either within the
enclosure or within the designated hearth area.
3.k Hearth (Domestic Installations)
HEARTH REQUIREMENTS DOMESTIC SUMMARY TABLE
Chilli Billie, no enclosure 12mm superimposed, stove fixed to
hearth (Stove anchor plate available)
Chilli Billie in enclosure
Hearth is integral to enclosure, stove
fixed to enclosure & enclosure fixed to
floor (Stove anchor plate available)
Hearth in front of stove 225mm
Do not place any soft furnishing within 1150mm of the stoves
Hearth both sides of stove 150mm
If there is any risk of ignitable materials coming into contact with the surface of the
stove - or in the presence of the young or infirm, a fireguard should be provided
(manufactured to BS 8423).
3.j Fireguard - Domestic/Glamping & Leisure
3.i Co Alarm and Smoke Alarm - Domestic/Glamping & Leisure
A CO alarm and smoke alarm should always be fitted
A suitable CO alarm is one that has been independently tested and CE marked against
the requirements, BS EN 50291-2. Improper selection of a CO alarm may result in
CO detection being limited and decrease the time available for occupants to vacate
premises safely. The CO alarm should be axed into a permanent position, within a
distance of 1m to 3m away from the stove.
• Make sure the floor can take the weight of the stove, the flue, the hearth/enclosure
and any decorative surround
• The stove and enclosure should not be able to be moved or disturbed by foot trac
eg. a person walking by on a sprung floor in a house or a non fixed floor in yurt
3.h Floors - Domestic/Glamping & Leisure
Page 15 of 43 www.chillipenguin.co.uk

If the structure that the Chilli Billie is being installed in has a non-permanent shell or floor
we recommend a solid base for the enclosure. This is to provide a stable level base of
support for the stove and flue system. This base should be placed directly onto the ground
rather than on top of a superficial floor surface and should be completely level. This is to
avoid any possibility of disturbance to flue joints/stove by foot trac.
• The stove should be fixed to the enclosure or hearth
• The enclosure if used, should be fixed to the floor or hearth
• combustible materials, including wood should not be stored either within the enclosure
or within the designated hearth area.
3.l Hearth (Glamping or Leisure Accommodation)
HEARTH REQUIREMENTS NON DOMESTIC SUMMARY TABLE
Chilli Billie, no enclosure
12mm superimposed, placed on flat level
stable ground, stove fixed to hearth
(Stove anchor plate available)
Chilli Billie in enclosure
Hearth is integral to enclosure, stove
fixed to enclosure & enclosure fixed to
floor (Stove anchor plate available)
Hearth in front of stove 225mm
Hearth both sides of stove 150mm
Do not place soft furnishings within 1150 mm of the stoves.
Spares are available through your local Chilli stockist or
our online shop. There are diagrams online to help you
identify the correct parts and advice about how to fit:
www.chillipenguin.co.uk/FAQ/looking-after-your-penguin
Page 16 of 43

• In some installations a heat shield may be advised but we recommend that heat
shielding cannot achieve more that a 50% reduction in distances to combustibles.
• A heat shield must include an air gap between the heat shield and the wall so the heat
is not transferred, see diagram below.
• The penguin enclosure is a form of heat shield.
3.m Heat Shielding
PENGUIN ENCLOSURE
Our penguin enclosure (round and square options) maintain the recommended distances
to combustibles below, to the rear and to the sides. They are made from a double skin
of steel with an air gap between the skins. The air gap is open top and bottom to allow
the free flow of air. It should be sited a minimum of 50mm from combustible walls. If you
are having a bespoke heat shield made, PLEASE take extreme caution, see the following
section.
HEAT SHIELDING - METAL/INSULATION BOARD
If you are not using a penguin enclosure and the structure of the building or surrounding
area is combustible, you can construct a wall mounted heat shield. We recommend that
this is double skinned, with the outer layer made of steel and the inner layer made of
either steel or cement board (A1 fire rated cement and glass reinforced insulation board),
illustrated below. A single skinned heat shield is not sucient for a Chilli Billie. The
recommended air gap must be maintained, to allow cool air to circulate. The distances
should be maintained using metal fixings or brackets. Refer to the distances shown in our
insulation diagrams.
The following diagram illustrates the minimum requirements.
10mm Cement tile board
Combustible Wall or Surface
Steel heatshield
10mm Air gap
30mm Air gap
Page 17 of 43 www.chillipenguin.co.uk

HEAT SHIELDING MINIMUM REQUIREMENTS
The heat shield should extend up to the extremities of the hearth, at least 150mm either
side of the stove, 200mm above the top of the appliance and have nothing above it
to hinder the circulation of air eg a shelf, note that the heat shield is also providing
protection for the single walled connecting flue. With a heat shield the single wall flue
needs to maintain 1.5 x the flue diameter from combustibles. Without a heat shield this
would be 3 x the flue diameter. Our recommended distances are shown in the installation
diagrams.
Page 18 of 43
3.n Heat Shielding Flue
• It can be overlooked that the flue must maintain distances from combustibles as
well as the stove
• If the room size is limited you are likely to need to consider heat shielding the length
of the single skinned flue (refer to heat shielding section). Double skinned flue
recommended for glamping purposes.
• Once in double skinned flue the distance to combustibles are reduced, see table below
Single skinned flue - only to be used as a
connector in glamping situations
SUMMARY TABLE
Chilli Billie, no enclosure
• Distance to combustibles =
3 x diameter oue
• Max length for single walled flue is
1800mm (in domestic setting)
Double skinned flue - must be used in
glamping/leasure accommodation
• Distance to combustibles = 50-75mm
depending on flue manufacturer
As flue exits the ceiling / roof / wall it must be double skinned (See installation diagrams)