Fire dept GD8 RB User manual

GD8 Recessed Burner –Wall Switch
Installation Guide
Operating Instructions
Warranty

Version: August 2020 2
GD8 RB Installation Guide, Operating Instructions & Warranty
IMPORTANT!
This gas appliance must be installed to AS/NZS 5601.1:2013 by a qualified person and in accordance with
these instructions. Failure to install the appliance correctly will void your warranty and may cause a fire. This
appliance should not be modified under any circumstances.
Under no circumstances should any combustibles such as paper, wood or coal be used in this appliance.
It is recommended that you have this appliance serviced annually by a qualified technician.
Warranty repairs must be carried out by a ‘The Fire Dept.’ authorised technician.
This appliance must ALWAYS terminate/flue outdoors.
Young children, elderly or infirm should be supervised to ensure that they are careful with the appliance.
Clothing and other flammable materials should never be placed near the appliance.
Please note that parts (near the flame) of this appliance, particularly the steel surrounding, become extremely
hot during operation and can result in serious injury and burns if touched. It is therefore recommended that a
fireguard complying with BS 8423:2002 is used in the presence of young children, the elderly or infirm.
NOTE: This GD8 RB appliance is fitted with an Oxyprotector (Oxygen depletion) pilot. Under NO
circumstances should this pilot be replaced or removed.
The GD8 RB installation process consists of 8 steps Page
Step 1: Unpack and ensure all components are correct and undamaged 3
Step 2: Install plinth (if required) 3
Step 3: Install appliance into cavity 3
Burner Tray Removal Process 4
Burner Tray Installation Process 5
Step 5: Connect and test electrical supply 14
Step 6: Connect gas supply and commission 16
Step 7: Lay the firebed 17
How to lay River Rocks Firebed –GD8 1200 20
How to lay River Rocks Firebed –GD8 1400 & 1600 21
How to lay Beach Driftwood Firebed –GD8 1200 22
How to lay Beach Driftwood Firebed –GD8 1400 & 1600 23
How to lay Forest Logs Firebed –GD8 1200 24
How to lay Forest Logs Firebed –GD8 1400 & 1600 25
Step 8: Show owner how to operate appliance 26
GD8 Recessed burner operating instructions 27
Troubleshooting 27
Product warranty 28
Information in this installation guide may be subject to change without notice.
Please ensure that you have the current version before beginning installation.
If you have any queries, please contact ‘The Fire Dept.’on 0800 888 550

Version: August 2020 3
Step 1: Unpack and ensure all components are correct and undamaged
•Appliance
•Box of firebed mediums
•Flue kit
Step 2: Install plinth (if required)
•If the appliance is to sit on a plinth, ensure it is
capable of supporting a 350kg load.
•There is no clearance requirement for the base of
the appliance. It may safely sit directly upon
combustible (eg. timber) and non-combustible
(eg. concrete) materials.
Step 3: Install appliance into cavity
•Before installation, confirm all minimum
clearances from the outside surfaces of the
appliance to the surrounding enclosure are no
closer than 25mm from combustible materials
and 5mm from non-combustible materials.
•The exception to these minimum clearances is
the base and the front surround panels of the
appliance, the base can safely sit directly upon
combustible (e.g. timber) and non-combustible
(e.g. concrete) materials, refer to the appropriate
appliance specification for the correct clearance
requirements. Ensure the framing is capable of
supporting a 350kg load.
•If a gas supply pipe has already been run to the cavity, ensure 1000mm of 3/8 soft copper tube is available
at the centre of the cavity, as this is where the copper tube with the gas supply enters the appliance.
•If an electrical supply cable has already been run to the cavity (must be a minimum of 1.0mm 4 core cable),
ensure that the cable reaches the centre of the cavity, as this is where it will enter the appliance.
•In order to access the fixing slots in the base of the appliance, and the gas and electrical connections, it is
necessary to first remove the burner tray.

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Burner Tray Removal Process
Cover and end cap removal
GD8 RB Pilot cover
This model has one pilot
cover.
•Remove the stainless steel pilot cover (2 x
screws) at the pilot end of the burner.
GD8 RB Burner end
caps
This model has two end
cap covers, one at each
side of the burner.
•Remove the stainless steel burner end caps
(3 x screws on each cap) at either end of the
burner tray.
LPG
Natural Gas
GD8 RB 1200
Input 18-28 MJ/h
One gas injector at the pilot
side of the burner tray.
•Remove the burner tray by carefully pushing
it away from the pilot and lift the pilot end of
the burner tray, lift the burner tray up and
away from the pilot in one movement.
•Stand the burner tray on its end and lean
against a stable surface.
•Remove the burner tray by carefully pushing it away from the
pilot and lift the pilot end of the burner tray, lift the burner tray up
and away from the pilot in one movement.
•Stand the burner tray on its end and lean against a stable
surface.
GD8 RB 1400
Input 20-28 MJ/h
Two gas injectors one at the
right and one at left hand
sides of the burner tray.
GD8 RB 1600
Input 30-38 MJ/h
Two gas injectors one at the
right and one at left
•Remove the burner tray by carefully pushing
it away from the pilot and lift the pilot end of
the burner tray, lift the burner tray up and
away from the pilot in one movement. Ensure
that the gas injector at the left hand side is
not damaged as the burner tray is lifted out.
•Stand the burner tray on its end and lean
against a stable surface.
•On the pilot side gas injector, loosen and spin back the 12mm
brass nut away from the burner tray.
•On the non-pilot side injector, loosen both the 12mm brass nuts
all the way to the end of the injector. The injector will need to be
pushed away from the burner tray.
•Remove the burner tray by carefully pushing it away from the
pilot and lift the pilot end of the burner tray, lift the burner tray
up and away from the pilot in one movement.
•Stand the burner tray on its end and lean against a stable
surface.
Pilot side Gas Injector
Non-pilot side Gas Injector
Pilot burner end
cap
Non pilot burner end
cap
Pilot cover

Version: August 2020 5
Burner Tray Installation Process
LPG
Natural Gas
GD8 RB 1200
Input 18-26 MJ/h
One gas injector at the
pilot side of the burner tray.
•Install the burner tray by carefully lowering
the end opposite from the pilot meanwhile
holding up the pilot end, lower the burner tray
down and move towards the pilot in one
movement.
•Ensure the burner tray is located correctly
into the burner bracket and the jets are
aiming into the burner tube inlet holes.
•Install the burner tray by carefully lowering the end opposite
from the pilot meanwhile holding up the pilot end, lower the
burner tray down and move towards the pilot in one movement.
•Ensure the burner tray is located correctly into the burner
bracket and the jets are aiming into the burner tube inlet holes.
•On the pilot side gas injector, gently tighten (do not over tighten)
the 12mm brass nut closest to the burner tray.
GD8 RB 1400
Input 20-28 MJ/h
Two gas injectors one at the
right and one at left hand
sides of the burner tray.
GD8 RB 1600
Input 30-38 MJ/h
Two gas injectors one at the
right and one at left hand
sides of the burner tray.
•Install the burner tray by carefully lowering
the end opposite from the pilot meanwhile
holding up the pilot end, lower the burner tray
down and move towards the pilot in one
movement.
•Ensure the burner tray is located correctly
into the burner bracket and the jets are
aiming into the burner tube inlet holes.
•Install the burner tray by carefully lowering the end opposite
from the pilot meanwhile holding up the pilot end, lower the
burner tray down and move towards the pilot in one movement.
•Ensure the burner tray is located correctly into the burner
bracket and the jets are aiming into the burner tube inlet holes.
•On the non pilot side injector, gently tighten both the 12mm
brass nuts. The injector will pull towards the burner tray.
•On both the non-pilot and pilot side gas injectors, gently tighten
(do not over tighten) the 12mm brass nuts closest to the burner
tray.
Cover and end cap installation
GD8 RB Oxygen Depletion
Pilot
•Under NO circumstances should the pilot
be replaced or removed,
GD8 RB Pilot cover
This model has one pilot
cover.
•Replace the stainless steel pilot cover (2 x
screws) at the pilot end of the burner.
GD8 RB Burner end
caps
This model has two end cap
covers, One at each side of
the burner
•Replace the stainless steel burner end caps
(3 x screws on each cap) at either end of the
burner.
Non-pilot side Gas Injector
Pilot side Gas Injector
Non pilot burner
end cap
Pilot burner end
cap
Pilot cover
Oxygen depletion pilot

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•Slide appliance into position and ensure that it complies with the minimum clearances required (25mm for
combustibles, 5mm for non-combustibles) to the surrounding enclosure. The exception to these minimum
clearances is the base and the lintel panels of the appliance, the base can safely sit directly upon
combustible (e.g. timber) and non-combustible (e.g. concrete) materials, refer to the appropriate appliance
specification for the correct clearance requirements. Ensure the framing is capable of supporting a 350kg
load.
•In order to provide maximum positioning flexibility, the base of the appliance has two fixing brackets with two
30mm long slots in each.
•The two fixing brackets will clamp the appliance into position. Locate the fixing brackets and mark out and
drill fixing holes through the 30mm slots in the fixing brackets. Ensure holes are drilled in the centre of the
slots to allow maximum positioning flexibility. Clear out any debris from drilling.
•Ensure the appliance is level and pack up corners to suit where necessary. Fix bolts/screws into floor. Check
and ensure unit is level.
•Once the appliance is fixed into position the outer 2mm steel lintel panel can be bolt/screw fixed to the cavity.
•In order to provide maximum positioning flexibility, the outer 2mm steel lintel panel has two side fixing
brackets with two 30mm long slots in each.
Outer 2mm steel lintel panel
Side fixing brackets

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•The two side fixing brackets will hold the outer 2mm steel lintel panel in position. Locate the fixing brackets
(see correct specifications or general assembly drawings) and mark out and drill fixing holes through the
30mm slots in the Side fixing brackets. Ensure holes are drilled in the centre of the slots to allow maximum
positioning flexibility. Clear out any debris from drilling.
•Ensure the Side fixing brackets are level. Fix bolts/screws to the
side fixing brackets to each side of the cavity.
•The outer 2mm steel lintel panel will fit snugly over and fix to the
side fixing brackets.
•Install the burner tray by following the ‘Burner Tray Installation Process’ in this guide.

Version: August 2020 8
Firebox Lining Removal Process (if required)
•In some circumstances (eg. the need to reduce overall weight so the appliance can be lifted up stairs), it may
be necessary to remove (then replace) all the firebox lining.
………………
•The GD8 has four fire box lining options: Fire bricks, Steel, Dark tile & Client supplied.
•Particular care should be taken when removing and replacing the chosen Fire lining into the appliance.
Failure to place the firebox lining correctly may result in the appliance performing inefficiently.
Fire Brick lining:
Herringbone - Hand cut fire bricks, 230mm x 25mm x 45mm.
Finish - Honed surface with grey grout.
Repair grout. To grout all joints and fill all shrink back cracks
during appliance installation.
Steel lining:
Mild steel –2mm.
Size –Cut and folded to suit appliance.
Finish –Matt black paint.
Dark tile lining:
Black slate –9mm.
Size –600mm x 600mm cut to suit.
Finish –Dark slate.
Client-supplied lining: Requirements
Non-combustible and heat resistant.
Size –maximum thickness 45mm
Size –Minimum height for tiles 500mm
All measurements must be confirmed on site.
Finish –Robust and self-supporting. Example of a client -supplied fire box lining

Version: August 2020 9
This GD8 RB appliance is supplied with the chosen firebox lining or ready for the client-supplied firebox lining.
Note: Take care when removing the top fixing bracket. The top of the Fire box lining will fall forward with the
bracket removed.
1. Remove the top three lining fixing brackets. 5mm cap screws.
2. Allow the top of the lining to fall forward.
3. Carefully lift the lining up and out of the base channel.
4. Place the lining in a safe place.
5. The lining on the base (either side of the burner) fits into the channel.
6. Remove the base lining by carefully lifting the lining at the joint or at one end.
7. To refit the firebox lining simply reverse the removal process.
Lining fixing brackets
Lining to sides & back
Base channel
Lining to base

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Step 4: Install flue and connect to appliance
•Flue installation must meet the requirements of AS/NZS 5601.1:2013 and comply with all local council
requirements and be installed and certified by a suitably qualified person.
•Refer to appropriate ‘The Fire Dept’ product specifications for specific minimum requirements. Only follow
the ‘Wall cowl assembly details’ in this guide if the flue is to be terminated through a wall.
•A 25mm clearance from combustible materials, 75mm clearance from wiring and plastic pipes and a
minimum of 5mm from non-combustible materials is required when installing a flue system for any appliance
supplied by ‘The Fire Dept.’.
•The flue installation requires a restriction free cavity from the top of the firebox (flue spigot) to the outside
atmosphere.
•Air flow must be unobstructed from the firebox to the inner flue and from the heat shield to outer casing
allowing air to circulate from the firebox to the flue casings to the atmosphere.
In-Line Fan assembly details
Step 1:
Step 1:
Connect the flue and outer casing to the firebox
1. Make sure the In-line fan has adequate access for future maintenance.
2. Run the flue from the appliance to the location of the In-line fan.
3. Run the outer casing from the appliance to finish 50mm shorter than the flue.
Step 2:
Connect the in-line fan to the flue and outer casing
1. Fit the flue over the inlet spigot to the In-line fan.
2. Fix the flue to the inlet spigot at the in-line fan.
Step 3
Complete the flue installation
1. Finish the casing with a 50mm gap to the in-line fan.
2. Complete the flue installation .Refer to appropriate’ product specification for
fixing details and specific minimum requirements.
Flow from In-Line
Fan to termination
Flow from firebox
to In-Line Fan

Version: August 2020 11
Different cowl terminations
Option 3A: In-Line Fan (vertical exit)
In-line fan
Vertical exit
Casing cover
Flue system
F79 –3.6m Flue In-Line fan shown
In-Line Fan

Version: August 2020 12
Option 3B: In-Line Fan (horizontal exit)
In-line fan
Horizontal exit
F78 –3.6m Wall In-Line fan shown
In-Line Fan
Flue system
Wall
cowl

Version: August 2020 13
Wall cowl assembly details
(for wall cowl + wall cowl fan installation)
Step 4:
Fit the front
panel
To fit the front
panel reverse
steps 1 to 3
Step 1:
Remove 5mm cap screw
Step 2:
Lift front panel
The front panel is hung on hocks
Step 3:
Remove the front panel
Fit Wall cowl into position
Step 1:
Timber framing
Set-up timber framing to suit
wall cowl.
Step 2:
Fit wall cowl into position
Fix will cowl into position
through the angle surround.
Step 3:
Flash wall cowl
Fit flashing in
accordance with NZBC.
Step 4:
Complete wall cladding
Fit wall cladding in accordance
with NZBC
Fit wall cladding into Wall cowl front panel (optional)
Step 1:
Remove front hot panel
1. Hot panel is fixed to back
panel with 4 x 5mm
counter-sunk cap screws.
Step 2:
Fix sub-straight into wall cowl
1. Cut sub-straight to suit (sub-straight not supplied)
2. The 4 x 5mm counter-sunk cap screws can be
used to hold the sub-straight in place.
Step 3:
Fix cladding into wall cowl
1. Adequately fix the cladding into the
wall cowl.

Version: August 2020 14
Step 5: Connect and test electrical supply
•All electrical connections must meet the requirements of AS/NZS 3000 standards and be installed
and certified by a suitably qualified person.
•In order to access the electricals, it is necessary to first remove the burner tray cover.
•Remove the burner tray by following the ‘Burner Tray Removal Process’of this guide.
•With the burner tray removed the electrical connections between the appliance and the wall isolation switch
can be seen, use 4 core (minimum 1mm) cable from the wall isolation switch.
•Following these connection details, using the 4 core cable that has been run at site, connect the wall
isolation switch to the appliance
•IMPORTANT: Before testing, ensure the gas valve is
turned OFF.
•Test electrical functions by switching the bottom High/Low switch to LOW, then switch the appliance ON
using the top On/Off switch.
•After approximately five seconds, the pilot will spark. Because the gas supply is turned off, the pilot will spark
for approximately five seconds then automatically switch off.
•NOTE: GD8 models have both LOW and HIGH settings.
•Switch to HIGH setting. Ensure that a red light appears on electrical controller.
•Switch the appliance OFF. Electrical testing is complete.
•Install the burner tray by following the ‘Burner tray installation process’ in this guide.

Version: August 2020 15

Version: August 2020 16
Step 6: Connect gas supply and commission
•Gas installation, connection and commissioning must meet the requirements of AS/NZS 5601.1:2013
and be installed and certified by a suitably qualified person.
•In order to access the gas supply and testing area, it is necessary to first remove the burner tray.
•Remove the burner tray by following the ‘Burner tray
removal process’in this guide.
•Connect 3/8 soft copper pipe to main valve.
•Leak test all joints.
•Switch the appliance ON.
•Test / adjust high pressure first (using the outer brass nut)
and then the low pressures against rating plate
specifications.
•In the unlikely event that the rating plate is not attached, Do Not commission the appliance and contact The
Fire Dept immediately.
•Switch the appliance OFF.
•Install the burner tray by following the ‘Burner Tray Installation Process’ in this guide.
•Switch the appliance ON.
•Note: due to lack of firebed, it may be necessary to manually light burners.
•Switch the appliance OFF
•Lay firebed in accordance with instructions in Step 7 of this guide.
•Send gas certificate to appropriate person.

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Step 7: Lay the firebed
•The GD8 Recessed Burner has three firebed options: River Rocks, Beach Driftwood & Forest Logs.
•Particular care should be taken when placing the chosen firebed mediums into the burner tray. Failure to
place the medium correctly may result in the appliance performing inefficiently.
•Open the firebed cardboard box and identify firebox mediums.
River Rocks option has two firebed mediums:
Vermiculite –3 bags
White rocks –large and small
Beach Driftwood option has three firebed mediums:
Vermiculite –3 bags
White rocks –large and small
Driftwood –large and small
Forest Logs option has three firebed mediums:
Vermiculite –3 bags
White rocks –large and small
Logs –large and small

Version: August 2020 18
How to lay Vermiculite
•Beginning in the middle at the back of the burner,
carefully empty the bags of vermiculite into the
burner tray.
•Ensure not to spill any vermiculite in cavities
in front of and behind burner tray.
•Do not pour vermiculite directly into burner slots.
•Fill area behind burner up to top of burner tray.
Use hand to spread out and push under burner.
•Fill up area in front of burner and gently pat
down vermiculite to ensure it is spread evenly
throughout the burner tray.
•Using a small Allen key (or similar), remove any
vermiculite that may have fallen into burner slots.

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•If natural gas is being used, leave burner slots
slightly exposed.
•If LPG is being used, lightly cover burner slots
in a thin layer of vermiculite by adding at back
of burner tray and gently sweeping forward.
•If LPG is being used, small burner slots should
be just visible.
•Vermiculite layer complete.

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How to lay River Rocks Firebed –GD8 1200
•Lay large rocks first, in these positions.
•Lay small rocks next, in these positions.
•Switch the appliance ON at ‘HIGH’ setting to check how flame looks. The flame will take 10-20 seconds to
light fully.
•IMPORTANT: the flame effect should look natural and non-uniform, running the entire length of the burner.
•Common flame effect issues are:
•Flame touching edge of burner tray.
•Missing flames along length of burner.
•Both these issues can be resolved by switching the appliance OFF and slightly repositioning rocks and logs
at the problem areas.
•Repeat this switching On/Off and repositioning until a natural and non-uniform flame effect is achieved.
•Once a natural and non-uniform flame effect is achieved, switch the appliance to ‘LOW’ setting and ensure
the flame effect, although smaller, still looks good.
•Switch the appliance OFF.