Esse 500 Series Assembly Instructions

1
500
MULTI-FUEL STOVE
INSTALLATION & USER INSTRUCTIONS
(TO BE LEFT WITH THE CUSTOMER)
UK & Ireland
12
ESSE Engineering Limited
, Ouzledale Foundry, Long Ing, Barnoldswick, Lancashire,
BB18 BN
Tel: [phone], Fax: [phone] , e-mail: [email protected]
Website: http://www.esse.com, On-line store: http://www.esseparts.com
Your ESSE stove is guaranteed against defects arising from faulty manufacture for one year subject to the following
express conditions. Failure to comply with these conditions will invalidate the guarantee.
•Your ESSE dealer or a suitably qualified engineer must install the stove. Upon installation the receipt
must be kept as proof of purchase.
•The guarantee is one year from date of purchase.
•The guarantee does not cover parts deemed to be replaceable in the normal usage of the stove. These
parts are: firebars, ash pan, side and back bricks, base protection plates, baffle, door rope seal, fuel bar,
door glass.
If you have cause for dissatisfaction with your stove, you should first contact your ESSE dealer, who will bring your
concerns to our attention, We will assess the nature of the complaint and either send replacements parts for your
dealer to fit, or nominate a regional engineer to inspect the appliance and carry out any remedial work that may be
necessary. If the fault is not actually due to faulty manufacture but some other cause i.e. misuse, failure to install
correctly, or failure to service at regular intervals, a charge will be made to cover the cost of the visit and any new
parts required. In the 1
st
year ESSE will only deal with the dealer direct.
Only genuine ESSE spare parts are recommended, Parts that may need occasional replacement are:
Fire bricks
Firebars
Ash pan
Side and Back Bricks
Base Protection Plates
Baffle
Fuel Bar
12/09
Conditions of Guarantee
GUARANTEE
How to Proceed With a Complaint
Spare Parts

2
General Safety Notes Page 2 Dimensions and Clearances Page 6
Installation Instructions Page 2 Installing the Stove Page 6
Chimney and Fuel Page 3 Operating Instructions Page 8
Flue Draught Page 4 Wood Burning Page 9
Flue Stabilizer Page 5 Solid Mineral Fuel Burning Page 10
•Properly installed, operated and maintained, this appliance will not emit fumes into the dwelling. However
occasional fumes from de-ashing and re-fuelling may occur. Persistent fume emission is potentially
dangerous and must not be tolerated. If fume emission does persist, open doors and windows to ventilate the
room. Let the fire burn out or eject and safely dispose of fuel from the appliance. Once the fire is cold, check
the flue and chimney for blockages and clean if required. Do not attempt to relight the fire until the cause of
the fume emission has been identified and corrected. Seek expert advice if necessary.
•Do not fit an extractor fan in the same room as the appliance.
•An adequate air supply for combustion and ventilation is essential in accordance with Building Regulations
Document J Section 2. Air openings provided for this purpose must not be restricted.
•It is important that flue ways are cleaned frequently and the chimney swept regularly. Also the stove must be
maintained in good mechanical order. The chimney should be swept at least once per year for smokeless fuel
and a minimum of twice per year for other fuels.
•If the chimney was previously used for an open fire, it is possible that the higher flue gas temperatures
generated by the stove may loosen deposits that were firmly adhering to the inner surface of the chimney and
cause blockage of the flue pipe. We recommend that in such a situation a second sweeping of the chimney
should be carried out within one month of regular use of the stove after installation. Also, lock open or
remove any existing dampers in the flueway.
•Should it be likely that children, aged or infirm people approach the fire, then a fireguard should be fitted.
•Avoid the use of aerosol sprays in the vicinity of the stove when it is in operation.
The installer has a responsibility under the Health and Safety at Work Act 1974 to provide for the safety of persons
carrying out the installation. Attention is drawn to the fact that fire cement is caustic and hands must be washed
thoroughly after use. The appliance is heavy and care must be taken during handling. Although the appliance does
not contain asbestos products, it is possible that asbestos may be disturbed in existing installations and every
precaution must be taken.
These instructions give a guide for the installation of the appliance but in no way absolves the installer from
responsibilities to confirm to British Standards, in particular BS8303 and BS6461, relating to the installation of solid
fuel appliances. The installation should also comply with local Building Regulations and Local Authority Bye-Laws.
The stove must be placed at least 40cm away from any combustible materials. If necessary, any adjoining walls
should be protected from the effects of heat.
CONTENTS
GENERAL SAFETY NOTES
INSTALLATION INSTRUCTIONS
3
The successful operation of the ESSE 500 relies on the adequate performance of the chimney to which it is
connected. The chimney must:
•Have an internal cross section of no less than 320cm
2
(200mm dia). If a flue liner is used it should be 125mm
(5'') diameter and suitable for solid fuel.
•Be a minimum 4.6m high from hearth level to pot.
•Be terminated at least 1m above roof level so that the chimney does not terminate in a pressure zone (see
Fig.2)
•Be free from cracks, severe bends, voids and obstructions.
•Be connected to this one appliance only.
•New chimneys must be built in accordance with local building regulations.
•If the stove is installed as freestanding appliance, it should not support any part of the chimney.
•Voids in the chimney should be avoided, as these will prevent a steady flue draught.
•The stove flue pipe should pass beyond the narrowing of the chimney (see Fig.1)
•Consideration should be given to falling soot. For rear outlet stoves it may be necessary to provide a soot
catchment area in the flue pipe so that soot does not settle in the path of the flue gases. The optional rear flue
box attachment available from ESSE has a detachable base that allows for fallen soot to be removed (see
Fig.1).
•A flue/chimney access point may also be required so that the state of the chimney can be checked and any
fallen soot removed.
•External flues must be insulated to prevent heat loss.
CHIMNEY AND FLUE
Fig. 1
–
Ideal Flue Connections

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The chimney can be checked, before the stove is installed, with a smoke pellet. If the chimney doesn’t pull the
smoke it may suggest the chimney needs attention (see the Flue Diagnosis Table, next page).
The flue draught test hole must be drilled in the flue pipe as close to the stove as possible and before any flue
draught stabiliser.
FLUE DRAUGHT
Measurements
Note: This test is only a guide as an apparently poor flue may improve o
nce the stove is installed, lit and the flue is
warmed. If, once the stove is installed, there is any doubt that the chimney is providing an adequate draught, a flue
draught reading can be taken with the stove lit. Two flue draught readings should be taken
, one with the stove at
minimum firing rate and one at maximum firing rate.
Fig. 1
–
Chimney and Flue Performance
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The stove should be lit and allowed to warm the flue thoroughly. The air controls can then be set so that the stove
burns on a low setting. Allow the burning rate to become steady. The flue draught reading should now be taken with
the primary air intake closed and the airwash control fully open.
The primary air intake can now be opened to allow the stove to burn at maximum rate. Give the stove some time for
the burning rate to become steady and then close the primary air intake, make sure the airwash control is fully open
and take a flue draught reading immediately.
Ideally, the flue draught readings should range between 1mm and 2.5mm wg. Any readings significantly outside this
range may indicate the need for remedial action.
Low flue draught symptoms: difficult to light and smoke coming into the room.
CAUSE REMEDY
Cold chimney Line the chimney
Chimney too short Extend the chimney
Down draught Relocate/extend chimney terminal. Fit an anti down draught cowl
Chimney diameter too large Line the chimney
Chimney obstruction Clear/sweep the chimney
Restricted air supply Check for competing draughts (other chimneys, extractor hoods/fans).
Fit an air vent if the room Is sealed.
High flue draught symptoms: fire difficult to control, fuel will not last, stove too hot, stove damage, chimney fire.
CAUSE REMEDY
External wind conditions
combined with chimney terminal Fit stabiliser cowl. Fit flue draught stabiliser.
A flue stabiliser can be fitted to reduce the draught through the stove if the flue draught is too high. The flue
stabiliser should be:
•Fitted in the same room as the stove
•The same size as the flue pipe
•Fitted no closer than 700mm to the flue outlet of the appliance.
Minimum
Maximum
FLUE STABILIZER

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The overall dimensions of the stove are shown in Fig.3. Fig.3 shows recommended distances between the stove and
surrounding combustible materials. As a rule, any surrounding combustible material should not exceed 80ºC. There
should be sufficient space around the stove for service work.
The construction of the hearth must conform to Building Regulations, must be firm, non-combustible and capable of
supporting the stove.
The flue pipe used to connect the stove to the chimney is 125mm (5'') in diameter. The stove supplied is ready for
top flue connection. The flue blanking plug supplied with the stove is used to block the rear flue outlet. To change to
rear connection the flue blanking plug can be moved to the top outlet. To access the bolts attaching the rear flue
connection, the fuel bar and the baffle must be removed (Fig.7-8) A rear flue box attachment, available from ESSE
or http://esseparts.com, allows the stove to be installed further out of any building recess. Fig.1 shows suitable flue
connections.
DIMENSIONS & CLEARANCES
INSTALLING THE STOVE
Positioning
Hearth
Flue Con
nection
Fig.3
–
Dimensions and Clearances
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1. The installation must allow for adequate chimney sweeping.
2. Avoid using bends greater than 45ºC to the vertical. All pipe flue sections should be as close to vertical as
possible.
3. All joints in the flue system must be effectively sealed.
4. All flue sockets must face upwards.
On completing the installation, check that all the internal components of the stove are positioned correctly.
Wood Burning parts: Check – Base plates, baffle, side and back bricks. See Fig.5-8.
Mineral Fuel Burning parts: Check – Grate bars, baffle, side and back bricks, fuel bar. See Fig.6.
•T HE B ASE P LATES
The base plates are available from your ESSE dealer as an optional extra and must be used if the stove is
operated in wood burning mode. See Fig.5. The base plates are not necessary when the stove is used in mineral
fuel burning mode. Baffle, fuelbar, bricks, grate bars, grate rest and riddle bar have to be removed before the
base plates can be positioned. Position the plates in the following order:
1. Rear base plate;
2. Side base plates;
3. Bottom base plate.
Remove in the reverse order.
•T HE F UEL B AR
1. Position the fuel bar as shown in Fig.7. Place the right of the fuel bar onto the right hand side brick rest.
2. Lower the left of the fuel bar down onto the left hand side brick rest.
Remove in the reverse order.
•T HE B AFFLE
Position the baffle as shown in Fig.8.
•T HE B RICKS
The bricks can be removed in the following order
1. Both back bricks;
2. The right hand side brick;
3. The left hand side brick (the left brick and the riddle bar are removed at the same time as shown in Fig.9).
Replace the bricks in reverse order.
Note: The fuel bar and grate bars need to be removed when placing or removing the baffle.
Note: The fuel bar and grate bars and baffle need to be removed before replacing the baffle.
Important Installation Notes
Positioning Internal Parts

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Fig.11. shows the stove and its controls and shows how the tool is used.
Included inside your stove are the following:
Baffle – position as shown in Fig.8.
Multi purpose operating tool – for lifting the ash pan, adjusting the primary air spinner, adjusting the air wash
control, operating the riddle and the door handle.
OPERATING INSTRUCTIONS
Your Stove
Fig.4
-
11
–
Operating the Stove
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If wood is to be burnt exclusively the best results will be obtained by removing the grate bars and the ash pan and
burning on the base of the stove. Fig.5 shows the stove in wood burning mode. The base protection plates are
available from your ESSE dealer and must be used when in wood burning mode. The advantages of burning on the
base are as follows.
•There will be more room inside the stove for larger pieces of wood/logs.
•Wood burns best in its own ash. Burning on the base of the stove will allow a layer of ash to build up which
will result in a more controllable fire.
Do not burn mineral fuels when the stove is in wood burning mode.
Before lighting the fire for the first time ensure that the baffle, the base protection plates, and the side and back
bricks are in position. Burning without either will result in the stove castings overheating and being damaged.
Open the air wash control and the primary air control fully. Place some tightly rolled paper on top of some crumpled
paper on the base towards the back of the stove. On top of this, place some small pieces of wood. Light the crumpled
paper and close the door. Once the fire becomes established add some larger pieces of wood. As the stove comes up
to temperature close the spinner. The burning rate of the stove can now be regulated by the rate at which fuel is
added and by adjusting the air wash control.
With the above in mind it is plain to see that the stove should ideally be run with the primary air inlet closed and the
air wash control open whenever possible. Another advantage of running the stove with the air wash open is that the
air is being drawn into the stove travels across the glass forming an air barrier between the glass and the fire bed
helping to prevent smoke particles sticking to the glass. If the fire dies down too low, opening the primary air control
for a short period will revive it.
To get the best results from your stove it is recommended that a wood stove thermometer (available from your stove
dealer) be fitted to the flue pipe above the stove, at eye level if possible. The figures below show the recommended
temperature of the flue gases.
115ºC – 245ºC (240ºF - 475ºF)
The flue gases should be in this temperature band for the safest, most efficient and most economical operation of
your stove.
Below 115ºC
This is below the condensation point of wood gases and may cause the build up of tar in the chimney, dirty the stove
glass and result in the inefficient burning of fuel.
Above 245ºC
Too hot. Heat will be wasted up the chimney. Excess heat may damage the stove or ignite an existing accumulation
of tar resulting in a chimney fire.
Correct Runni
n
g Temperatures
WOOD BURNING
Note: Wood burns most efficiently whe
n the air for combustion is supplied from above the fire bed rather than below.
The air supplied above the fire bed provides the oxygen necessary for the volatile gases (smoke), given off by the wood
as it heats, to combust. This ensures that the gases are
burnt and used to heat the stove instead of being wasted up
the chimney or condensing and forming tarry deposits inside the stove, in the flue or on the stove glass. Running the
stove with the primary air control open and the air wash control closed will
provide oxygen for the wood to burn on the
fire bed but will not provide air for the volatile gases above the fire bed to combust resulting in a smoky inefficient fire.
Lighting and Controlling the Fire

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Loading a large amount of wood into the stove all at once will reduce the temperature inside the stove. If the
temperature is too low, the gases given off from the wood will be too cool to combust resulting in a lot of smoke
covering the inside of the stove, including the glass, with soot. To combat this problem it is a good idea to increase
the temperature of the stove before loading by further opening the air inlets. Load the wood and leave the air controls
open until the moisture is driven out of the wood and the stove is back up to an efficient operating temperature. The
air inlets can then be reduced to hold the temperature steady. When loading wood, make sure that the end grain of
the wood in the stove is pointing away from the glass otherwise the moisture and gases coming from the end grain of
the wood will dirty the glass.
For best results use well seasoned hardwood such as Oak, Ash, or Beech. Allow wood to dry out under cover in
well-ventilated conditions for at least twelve months. Ideally moisture content should be between 15%-20%. Wood
is ready for burning when radial cracks appear in the end of the logs. Burning wood that is not seasoned will result in
tar being deposited in the stove, on the glass and in the flue ways. This build up of tar is a hazard and if it ignites
may cause a chimney fire. Resinous softwood burns well and gives a high output for short periods but not as
efficient and does not last as long as hardwood.
Peat is a fuel conveniently available in some areas and should be burned in the same manner as wood.
Before lighting the fire for the first time ensure that the baffle, and the side and back bricks are in position. Burning
without either will result in the stove castings overheating and being damaged.
Open the air wash control and the primary air control fully. Place some tightly rolled paper on top of some crumpled
paper on the base towards the back of the stove. On top of this, place some small pieces of wood and on top of that a
few small pieces of mineral fuel. Light the crumpled paper and close the door. Once the fire becomes established and
the fuel is burning, more fuel can be added. When the stove is hot and the fuel is no longer producing smoke, the air
wash control can be reduced. The burning rate of the fire can now be controlled with the spinner. As air from the
spinner flows up through the grate it will cool the grate bars preventing them from overheating and becoming
damaged. Reducing the spinner air inlet and introducing air only from the air wash will allow the fuel to burn but the
grate will not be cooled resulting in damage to the grate bars. When controlling the fire, the spinner should be altered
gradually. Reducing the primary air dramatically and all at once on a hot stove will cause the fuel to clinker and will
result in a build up of gases and smoke which could ignite with a bang the moment air is reintroduced.
Before adding a large amount of fuel, the grate should be de-ashed and the ash pan emptied. Add the fuel, sloping it
from the front coal bar up to the back of the stove to the level of the top of the back brick. Open the primary air inlet
and let the fire burn for a period on high rate in order to get the stove back up to temperature and drive off the
moisture and gases in the fuel. If a lot of smoke is produced on reloading, the air wash control can be opened further
to keep the smoke back from the glass. As the fire gets back up to temperature, reduce the air wash control and
reduce the primary air inlet to suit the burning rate. The exact setting of the air controls depends on a number of
variables including: the flue draught, the fuel used and the installation and so the best settings for your stove can
only be learned by experience.
Note: The above text shoul
d be used as a guide only. The ideal operation of your stove depends on a number of
factors, which vary with each installation, and so gaining experience operating your stove is the only way to learn its
best operation.
Types of Wood for Fuel
SOLID MINERAL FUEL BURNING
Lighting and Controlling the Fire
Extended Burning
Peat
Extended Burning
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The level of ash should not be allowed to build up to the level of the grate. If the level of ash becomes too high the
air through the grate will become restricted causing the grate bars to overheat and preventing the fuel from burning
efficiently.
The grate bars in the centre of the stove will wear more quickly than the ones at the edges. To ensure even wear,
swap the positions of the grate bars occasionally.
Ordinary bituminous house coal is not recommended and must not be burned in smoke control areas. Burning
bituminous house coal will result in a sooty stove and chimney, and the stove glass will require cleaning regularly.
There are numerous natural anthracites and manufactured smokeless fuels that will burn cleanly and have more
reliable burning characteristics. A list of these fuels and their suitability is produced by HETAS (www.hetas.co.uk).
Consult your local fuel merchant to find out what is available in your area. Petro-coke should not be used as it burns
very hot and may damage the stove castings.
The stove should only be cleaned when it is cold. The exterior can be dusted with a firm brush. Do not use a cloth, as
this will drag on the paint finish leaving lint on the surface. From time to time it may necessary to renovate the
extractor by repainting. High temperature stove paints in aerosol form are available from your stove dealer. Do not
use this form of paint until the stove is cold and always read the instructions on the container before starting to paint.
The door glass is made of a special heat resisting ceramic and may be cleaned when cold with proprietary glass
cleaning liquids and a dry cloth.
The following procedure should be followed if the stove is not to be used for a long period, summertime for instance.
Remove all the ashes from the grate and ash pan and use a vacuum cleaner nozzle to clean ash from the base of the
stove. Remove the baffle plate and brush the flue ways. Close the door and open the air inlet fully. This action will
allow air circulation through the flue ways and help to avoid corrosion and condensation.
T O ADJUST THE DOOR HANDLE (Fig. 12) – Undo the grub screw on the side of the door with an allen key (1), slide
handle out slightly (2) and relock the grub screw.
T O ADJUST THE DOOR HINGE (Fig. 13) – Open the door and locate the hinge block at the top & bottom of the door.
Insert allen key and unlock spindles (1). Slide door on spindles to adjust (2) then relock grub screws.
Ash Removal
Grate Bars
Mineral Fuels
Cleaning the Stove
Shutting Down the Stove (Long Term)
Fig.12
–
Adjusting the Door Handle
Fig.13
–
Adjusting the Hinges
DOOR HANDLE AND HINGE ADJUSTMENT