CVO Fire FR600 Technical document

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Rev-2
FR600
(with Manual Control)
HIGH EFFICIENCY WALL MOUNTED GAS FIRE
APPROVAL : BS7977-1:2009
TECHNICAL INSTALLATION MANUAL
The FR600 gas fire is available for Natural Gas (G20) only at a supply
pressure of 20mbar.
Serial Number ………………………………
Please quote this serial number when making a claim. Your Warranty is valid for 1 Year from
date of delivery. The Warranty card supplied is to be filled in and sent to
Spirit Fires Limited. 4 Beaumont Square, Aycliffe Industrial Park, Newton Aycliffe,
County Durham, DL5 6XN
The Instructions for Installation and Maintenance plus
User Instructions must be handed to the User once the
Appliance is Commissioned and retained for future
reference.

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Contents
Page 3 Introduction and Installation Requirements
Page 5 Appliance Efficiency Declaration
Page 6 Unpacking the Appliance
Page 6 Parts List
Page 6 Technical Data
Page 7 FR600 Dimensions
Page 8 Gas Burner Construction
Page 8 Restrictor Plate
Page 9 Building and Installation Work
Page 12 Connect the Gas Supply
Page 12 Fitting the Ceramic Pebbles
Page 14 Commissioning the Fire
Check Gas Pressure
Check for Spillage
Page 16 Fitting the Fascia
Page 17 Commissioning Checklist
Page 18 Oxygen Depletion Pilot System
Page 18 Spark Failure
Page 18 Warning Fire Guards and Hearths
Page 19 Exchangeable Parts
Page 20 Removing and Cleaning the Glass Panel
Page 21 Burner Removal
Page 22 Replacing Components
Page 24 Service and Aftercare Requirements
Page 25 Fault Diagnosis/Troubleshooting
Page 27 Gas Fire User Instructions

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Introduction & Installation Requirements.
Consumer Protection Information
As the manufacturer and supplier of heat products, we take every care, as
far as is reasonably practicable, that these products are so designed and
constructed as to meet the general safety requirement when properly used
and installed. To this end, our products are thoroughly tested and examined
before dispatch. IMPORTANT NOTICE: Any alteration that is not approved
by the appliance manufacturer could invalidate the approval of the appliance,
operation of the warranty and could affect your statutory rights.
Health and Safety Notice
Important: This appliance could contain some of the materials, indicated
below, that could be interpreted as being injurious to health and safety. It is
the user’s / installer’s responsibility to ensure that the necessary personal
protective clothing is worn when handling these materials, see below for
information.
Artificial Fuels, Mineral Wool, Insulation Material,
Refractory/Ceramic Fibres, Glass Yarn – may be harmful inhaled, may
be irritating to skin, eyes, nose and throat.
When handling avoid inhaling and contact with skin or eyes. Use disposable
gloves, facemasks and eye protection. After handling wash hands and other
exposed parts. If a vacuum is used for cleaning the coals or cleaning after
servicing / installation it is recommended that it be of the type fitted with a
HEPA filter.
•The FR600 has been designed and tested to the requirements of BS7977-
1:2009 and is suitable for use in GB (Great Britain) and IE (Ireland).
•The FR600 is a High Efficiency wall mounted gas fire for use with a
chimney or flue system.
•The FR600 incorporates a single gas control, which has a Piezo ignition
pilot, with variable setting between low and high settings.
•Like all appliances incorporating an aerated burner a low frequency noise
may be heard, this may be more noticeable on the low setting.
•The FR600 incorporates a safety device in the form of an Oxygen
Depletion System, which constantly monitors the oxygen in the room and
will cause the fire to switch off if the oxygen level reduces, for instance
due to a blocked flue. If this regularly occurs do not attempt to relight the
appliance until a qualified engineer has checked it.
•The installation must be carried out by a Gas Safe registered engineer in
accordance with National Regulations.
•Clearances between the fire and all combustible materials must conform
to National Regulations.
•This appliance is supplied as a complete fireplace package including gas
fire burner unit, enclosure and fascia. This fire must be installed and used
in accordance with these instructions.
•The builders opening or fireplace opening must be constructed of a non-
combustible material.

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•For some countries a non-combustible hearth must be fitted in front of
the fire in accordance with National Regulations (e.g. United Kingdom).
•Flue System: The FR600 can be used with a brick built chimney or a
lined flue with a minimum diameter of 125mm (5”). The chimney must
have a minimum effective height of at least 3 metres. The chimney
should be swept prior to installation if it has previously been used with
solid fuel. This is not necessary if the flue has previously been used with a
gas appliance or if it is a new installation. (see install section for full
details on the flue requirements). Any flue damper plate or flue restrictor
must be removed.
•Gas Supply: The appliance is for use on Natural Gas (G20 @ 20mbar)
only. Inlet is via an 8mm gas line to the isolation valve provided with the
fire. The gas connections must be in accordance with National
Regulations. If the gas line is longer than 1.5mtrs then the gas line should
be increased in diameter to 15mm and possibly larger depending on the
final length to ensure a steady gas supply. The fire is supplied with an
isolation valve inside the appliance. This must be used. When closed this
will allow the complete burner and control assembly to be disconnected
for maintenance or repair in accordance with National Regulations.
•The pilot light and flame sensing device fitted to this fire is also an
atmosphere sensing devise. If for any reason any part of the pilot
assembly is to be replaced ALL the assembly including the pilot burner,
thermocouple, electrode and injector must be exchanged complete for an
original manufacturer’s pilot assembly only. This atmosphere sensing
devise is not adjustable and must not be put out of action. The pilot light
shuts off both the main burner and pilot if evacuation of the combustion
products is interrupted. If the fire shuts itself off, do not use the fire, and
have the flue and fire checked by a suitably qualified person.
•The FR600 is operated by a manual control valve with piezo ignition
therefore no mains electrical supply is required. Please take some time to
learn the lighting procedure.
•The chimney or flue (unless new or previously used with a gas appliance)
must be swept before installation if it has been used for solid fuel.
•The fire front (fret) or fascia supplied must be used with this appliance.
The fascia must be installed with the fascia “floating” on the wall.
•Failure to install the appliance correctly could lead to prosecution. In GB
(Great Britain), the appliance must be installed by a competent person
i.e. GAS SAFE registered, in accordance with the GAS SAFETY
(INSTALLATION AND USE) REGULATIONS, the building regulations (or the
building regulations (Scotland) or the building regulations (Northern
Ireland). In IE (Ireland), the appliance must be installed by a competent
person and installed in accordance with the current edition of I.S.813
Domestic Gas Installation, the current building regulations.
•The glass front of this fire acts as a dress guard, conforming to BS 1945
(1997) however, a fireguard conforming to BS6539 (1997) must be used
to protect young children, the elderly or infirm.
•The appliance MUST NOT be used with the glass safety screen removed or
if it is damaged or cracked.

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•During initial usage, an odour may be evident. This is the starch binder
used during the manufacture of the fibre components of the fire, and
there are no harmful effects produced.
•During the normal operation of the fire some staining may appear on
some parts of the fire burner. This is quite normal due to the heat
generated by the appliance.
•During initial starting of the appliance condensation may be seen on the
glass and the flame may be unstable. This is normal with this type of
appliance and will disappear when the fire and flue system are warm.
•This is a high efficiency gas fire and generates a considerable amount of
heat from the top of the appliance. Care must be taken to prevent any
damage being caused to surrounding soft furnishing or decoration, e.g.
many embossed vinyl wall coverings may become discoloured if placed
too close to the appliance. Combustible material i.e. wall panelling or
wallpaper must be removed from behind the fire and fire trim.
•It is advised that this appliance is serviced annually, as it is more likely to
provide trouble-free operation.
•The fire does not require purpose built permanent ventilation as it
conforms to BS 5871-2: 2005 +A1: 2007 – Annex B (has a net heat input
of ≤7kW and a flue flow of ≤70m3/h
•This appliance becomes hot during operation therefore all areas must be
considered to be working surfaces.
Appliance Efficiency Declaration
EFFICIENCY CLASS – 1
GROSS EFFICIENCY – 74.5%
NOx CLASS - 4
The efficiency of this appliance has been measured as specified in:
BS7977-1:2009 - Specification for safety and rational use of energy
of domestic gas appliances – Radiant/Convectors.
The Gross calorific value of the fuel has been used for this efficiency
calculation. The test data from which it has been calculated has been
certified by Gastec at CRE Limited [notified body number 0558]. The
efficiency value may be used in the UK Government’s Standard Assessment
Procedure (SAP) for energy ranging of dwellings

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Unpacking the Appliance
Read these instructions fully before starting to install the fire.
Carefully examine the carton for damage before proceeding. If it is
obviously damaged, please contact the supplier over whether to proceed.
Remove the fire and examine its general condition. If satisfied by the
condition, proceed with the installation.
PLEASE NOTE no claims will be accepted for damaged or faulty
components once the appliance has been installed.
Parts List
•Fire is supplied as a complete unit with:
oGas Fire Body.
oSteel Fascia.
oCeramic Set.
oInstallation Booklet.
oFitting Kit.
Technical data
Pilot Assembly Marking SEAGAS P4-37D
Injector AC060 stamped “220”
Gas connection 8mm O.D. tube
Minimum flue diameter 125.0mm
Minimum flue height* 3.0m
Room Ventilation Not Required
Approximate weight 10kg
Gas Type G20 – I2H – Natural Gas
Gas Pressure 20mBar
Nominal Heat Input 3.7 kW, Gross
Nox level Class 4
Efficiency Class 1
Efficiency Rating [NET] 82.8%
Efficiency Rating [Gross] SAP 74.5%
*WARNING: THIS FIRE IS NOT AVAILABLE FOR LPG.

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FR600 Dimensions

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Gas Burner Construction
Take some time to review the burner construction taking note of the
positions of the main components and the required connections.
Before starting to install the appliance review the Data Plate fitted to the
appliance for the gas type and pressure requirements of the appliance.
Ensure these are correct for the property supply.
The fire features a manual control valve with a piezo ignition system. DO
NOT MAKE ANY ADJUSTMENTS TO THE VALVE. The flow rates are set at the
factory to the correct heat outputs. To check the input gas pressure the
isolation test point provided must be used [see commissioning section]
The Pilot assembly is a SEAGAS P4-37D. Do not make any adjustments to
the pilot assembly.
This Fire requires only the connection of an 8mm gas supply.
Restrictor Plate
The fire is supplied with a restrictor plate. In most installations this will not
be required however if the fire is to be installed in a Class 1 chimney with
excessive length fitting the restrictor plate will preserve the efficiency off the
appliance.

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Building and Installation Work
Prior to installation, ensure that the local distribution conditions
(identification of type of gas and pressure) and adjustment of the appliance
are compatible. Installation must be carried out by a Gas safe registered
engineer and must adhere to national and local legislations and regulations.
The appliance installation should be in accordance with the current version of
BS 5871-2, (which is BS5871-2: 2005 +A1: 2007 for the installation and
maintenance of gas fires, convector heaters, fire/back boilers and decorative
fuel effect gas appliances- Part 2: Inset live fuel effect gas fires of heat input
not exceeding 15kW, and fire/back boilers).
Before Starting
Building work should only commence after a thorough survey of the intended
location of the impending installation has been completed and it has been
established that the unit can be installed and operated without risk to the
owner or tenants of the property or their neighbours.
The fire can be used with a brick built chimney, a brick chimney lined with a
flue liner. This must have a minimum diameter of 125mm [or equivalent
area] and a minimum length of 3 meters. If a brick built chimney is used
that has been used previously with a solid fuel fire this must be swept before
installation. It is advised to perform a smoke test prior to installation to
confirm the chimney is working correctly. The flue must be sealed to the
fireplace enclosure inline with building regulations.
Gas Supply
Consult the Data Plate within the appliance to ensure the correct gas type
and pressure is available within the property. Before commencing to create
the fire opening for the inglenook unit note that a gas supply is required. The
gas supply pipe should run into the installed enclosure from either the rear,
left or right hand sides, the gas supply is best run through the left side of the
enclosure.
The fire has an 8mm inlet via an isolation valve. The fire also includes a
pressure test point elbow to test inlet pressure. The gas pipe work should be
routed into the enclosure via the available access holes. If the gas pipe work
is over 1.5mtrs in length it is recommended that the pipe work is increased
in diameter from this point to 15mm and possibly 22mm depending on the
length to the meter. This will ensure a stable gas supply.

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Building Work
Measuring from the floor surface, the intended location of the base of the
enclosure unit is marked onto the wall. The Fire enclosure should be located
centrally to the existing flue / chimney at your desired height. The area
indicated on the wall must be removed to house the Fire enclosure and
burner unit. In some installations it may be necessary to install a small lintel
above the opening, if so an allowance must be made to accommodate this
lintel. (The Fire does not have its own lintel).
The base of the chamber must be able to withstand the weight of the
appliance and must be sealed to ensure that all combustion products enter
the flue.
To comply with BS7977-1 a minimum depth of 236mm is required.
See below image for the construction opening sizes and clearances required.

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If this appliance is to be fitted above a hearth the base of the opening must
be a minimum of 50mm from the hearth.
If the fire is to be fitted without a hearth the minimum height from the base
of the fire is 100 mm.
Fitting the Fire
Before fitting the fire run an 8mm gas line into the chamber ready for
connection to the fire. The fire is supplied as a cartridge. Once a non-
combustible chamber has been created in line with the required dimensions
the fire can be lifted into the opening and secured to the wall. The gas pipe
should be fed through the appropriate hole in the enclosure ready to connect
to the isolation valve. It is advised to use the inlet on the left as this is the
easiest way to connect the gas line. The shaded area as shown on the image
on the previous page must be secure and manufactured of a non-
combustible material. This is the burner mounting area. By using screws and
plugs the fire must be screwed to the wall to create a seal. See image below.

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Connecting the Gas
The fire is supplied with an isolation valve mounted within the fire. Connect
an 8mm gas line to the isolation valve. See image below.
Add the Ceramic Pebbles to the Burner.
The fire is supplied with a set of ceramics. Once the fire is installed within
the non-combustible chamber and secure the ceramics must be placed on
the burner tray before lighting and commissioning the fire. Only ceramics
supplied with the fire must be used on this appliance.
Procedure:
1. Remove the glass panel as described on Page 20.
2. The stones must be positioned around the ribbon burner to ensure the
entire burner tray is covered. The stones have a flat side. This should
be positioned down.
3. Great care must be taken to ensure:
a. The ventilation holes in the burner tray are not blocked.
This can be achieved by carefully positioning the stones.
That no stones are positioned so that they interfere with
the flame or touch ribbon burner bar. If the fire is operated
with the stones within the flame the flame quality and emissions
from the fire will increase causing staining of the glass and
possible shutdown of the fire.
b. That no stones are placed on top of the pilot shield. If the
fire is operated with stones on the pilot shield it may cause the
fire to be unreliable.
4. Refit the glass panel as described on Page 20.
5. Review the images on the following pages to ensure the procedure has
been correctly followed.

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With the glass removed, note the position of the burner and pilot shield.
Carefully place the ceramics around the burner bar in an even pattern making sure
that no stones are placed on top of the burner or the pilot shield. The ventilation
holes in the burner tray should not be blocked (12 slots). This is possible by
carefully placing the stones in an irregular pattern. No stones should “touch” the
burner bar or interfere with the flame. (See image below)
Refit the glass panel ensuring the glass is pushed forward creating a seal.

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Commissioning the Fire
The fire is now ready to be lighted. Refer to the section “Lighting the Fire”
within the User section of the manual. Record all of the readings on the
Commissioning Check Sheet provided on page 17.
•GAS PRESSURE:
•All gas pressure tests must be done using the isolation point provided
within the fire [on the isolation valve]. Connect a correctly calibrated
manometer to the isolation point.
•Check gas soundness to ensure there are no leaks in the gas pipe
work. If leaks are found rectify this before lighting the fire. Note the
gas fire pipe work has been tested at the factory to 150mBar. Do not
loosen any of the joints within the appliance.
•Check the inlet standing pressure. This must be 20mBar +/- 1mBar.
•With other gas appliance in the home switched off, light the fire using
the handset and operate on full.
•Check the inlet pressure this must still be within the range of 20mBar
+/- 1mBar.
•With other gas appliance in the home switched on, light the fire using
the handset and operate on full.
•Check the inlet pressure this must still be within the range of 20mBar
+/- 1mBar.
•NOTE: If the pressure is out of range. Disconnect the appliance and
check the pipe work to the appliance. It may also be necessary to
contact the utility supplier to adjust the gas meter. Once correct
connect the appliance again and retest inlet pressure.

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•CHECKING FOR COMBUSTION PRODUCTS CLEARANCE:
•Light the fire and leave on Full setting for five minutes.
•Close all doors and windows.
•Run a smoke match along the top edge of the central appliance outlet
opening.
•[SEE IMAGE ABOVE].
•ALL SMOKE must be drawn into the opening. If spillage occurs leave
for 5 minutes and test again.
•If the test indicates that spillage is occurring and the flue
restrictor plate has been fitted, it should be removed and the
test repeated after the fire has cooled.
•Repeat the test with the doors open and any fans in other rooms in
operation.
•If spillage is detected the cause must be discovered and rectified. If
the fault cannot be corrected disconnect the fire from the gas supply
and seek expert advice. Causes of spillage can be – blockages in the
flue, down draft or insufficient ventilation in the room in which the fire
is installed.

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Fitting the Fascia
•The fascia is held in place by two M6 Bolts with Nylok Nuts.
These are pre-fitted to the fascia. On either side of the fire
chassis there is a bracket which matches up to the fascia bolts.
Remove the bolts from the fascia and offer up the fascia to the
brackets. Fit the bolts and nuts and tighten until the bolt is
secure however the bolt can still be rotated in the hole. This will
ensure the fascia moves easily.
•In the lower edges of the chassis there are two magnets. These
hold the fascia in place.
•To light the fire the fascia needs to be lifted from the bottom
edge and raised to gain access to the manual control knob. The
fascia becomes hot during normal operation.
•See image above for the safe lifting zone.
•The fire is now finished.
Brief the Customer
•How to light the fire and shut down the appliance.
•The customer must be told of the need for regular servicing of
the appliance, at least once a year.
•Complete the warranty card and give this to the customer. Give
the customer the instruction booklet.

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Commissioning Checklist
Flue Check Reading Pass/Fail
1. Flue is correct for appliance
2. Flue Flow test
3. Spillage test
Gas Check
1. Gas soundness & let by test
2. Standing pressure test
3. Appliance working pressure (on High Setting)
with all other gas appliances switched off.
4. Appliance working pressure (on High Setting)
with all other gas appliances operating on full.
Other
6. Does ventilation meet appliance requirements
Dealer and Installer Information
Dealer…………………………………………
Contact No…………………………………
Date of Purchase…………………………
Model No……………………………………
Gas Type……………………………………
Installation Company
…………………………………………………
Engineer…………………………………
Contact No…………………………………
Reg No……………………………………
Date of
Installation……………..…………………
This product is guaranteed for 1 year from the date of delivery, as set out in the terms and
conditions of sale. This guarantee will be invalid, to the extent permitted by law, if the above
Commissioning Checklist is not fully completed by the installer.

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Oxygen Depletion Pilot 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. Do not
attempt to bend or alter the flame head, thermocouple or aeration hole. Use
only genuine spare parts as similar looking parts from other appliances may
well give different or inferior performance and could lead to a hazard.
Spark / Ignition Failure
The gap between the pilot electrode and the pilot should be 3.5 – 4.5mm
and normally adjustment is not necessary (the electrode is very brittle). The
spark should jump across the gap between the electrode and the gas outlet
on the pilot head. To adjust the spark the glass panel will need to be
removed. Consult section in the manual.
Warning: Fire Guards & Hearths
In normal use consideration may be given to the use of a fireguard
conforming to BS6539 or BS6778, so that the approach to the
appliance is limited such that access to the flame is minimised
For some countries a non-combustible hearth must be fitted in front of the
fire in accordance with National Regulations (e.g. United Kingdom). It is
recommended that a fireguard conforming to BS6539 or BS6778 is used for
the protection of young children, the elderly and infirm.
The installer is to advise the user not to stand too close to the appliance for
prolonged periods of time and warn that loose clothing is particularly at risk
of burning due to the heat of the glass.
In addition, the installer is to advise the user against placing combustible
material directly in front of the appliance. Floor coverings, such as carpets,
are considered to be acceptable.

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Exchangeable Parts
Shown below is a list of exchangeable parts, these are separated into
categories, “User” & ”Engineer”. The parts listed under engineer must be
changed by a registered gas engineer only.
Spare parts are not returnable. CVO Fire cannot accept responsibility for
incorrect parts being ordered. When ordering replacement components or
requesting technical assistance, you should at all times quote the following
information: Type of fire & serial number as shown on Data Plate, the
component part number and description of fault. For Spare Parts please call
01325-327221 and ask for customer service.
ENGINEER REPLACEMENT PARTS
Part Code Description Replacement Method
AC043 PILOT ASSY P4-37D See Page 22
AC060 NG INJECTOR “220” See Page 22
USER REPLACEMENT PARTS
Part Code Description Replacement Method
KC123 GLASS PANEL See Page 20

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Removing and Cleaning the Glass Panel
The glass will require cleaning periodically. Condensation produced by the
products of combustion will create marks on the inside face of the glass
panel. The glass used on this appliance is special high temperature glass. If
it is damaged or cracked a replacement part must be obtained from the
manufacturer.
To remove the glass panel consult the image below:
The glass panel is held in place by a series of screws and a seal. Taking great
care remove all of the screws. The panel should now be free to lift off and
clean.
To clean the glass panel, use a clean damp cloth and ceramic glass cleaner
to remove any stains or deposits from the glass panel. Do not use scouring
pads as this may scratch the surface finish of the glass panel.
To refit the glass panel to the fire:
First inspect the seal. If it is damaged or broken a new seal must be
purchased from the manufacturer. To refit the glass it is the reverse of the
removal procedure. Ensure the metal brackets are pushed tight to the glass
to create a strong seal before locking the screws.