Firenzo Athena User manual

Please read this booklet and keep for future reference for the safe
installation and operation of your:
forte or
Athena
aqualux AG
AG = CLEAN AIR
All installations must be in accordance with these instructions. Consult
with the building authority having jurisdiction to determine the need for
a permit prior to commencing the installation. Failure to follow these
instructions may also void your fire insurance and warranty.
This unit has been tested to Appendix E & B of the joint
Australia/New Zealand Standard 2918:2001

Aqualux AG Installation
2
Please leave this manual with the owner after installation.
Your warranty card is enclosed and may be completed and returned to us.
INDEX
DIAGRAMS:
Page 4 Firebox, Fascia & Floor Protector Dimensions
Page 6 Builtin Fire Canopy Dimensions
Page 7 Builtin Fire Canopy Assembly
Page8,9,10,11 Builtin Fire Canopy Framing Guide
Page 13, 14 Raised Builtin Fire Canopy Framing Guide
Page 15 Cavity Chimney Termination
Page 18 Typical Insert Installation Diagram
Page 20 Insert Flue System for Masonry Fireplace
Page 21 Minimum Height of Flue Outlet
PAGE: ITEM:
3 1 Warnings
4 Firebox, Fascia & Floor Protector Dimensions
5 2 Floor Protector Requirements
6-12 3 Builtin Fire Canopy
13-14 Raised Builtin Fire Canopy
15 Built In Fire – Cavity Chimney Termination
16 4 Pre-Installation & Mantels
16-17 5 Assembly Instructions
18 Typical Insert Installation
19 6 Wetback
20 7 Insert Flue System for Masonry Fireplace
21 Minimum Height of Flue Outlet
22 8 Fascia Assembly & Installation
Athena
Forte

Aqualux AG Installation
3
Edited 2/5/2011
1. WARNINGS
THIS APPLIANCE SHOULD BE MAINTAINED AND OPERATED AT ALL TIMES
IN ACCORDANCE WITH THESE INSTRUCTIONS.
The Forte Aqualux AG and the Athena Aqualux AG has been tested to N.Z. Standards
AS/NZS 2918:2001.
If this heater is incorrectly installed a house fire may result. For your safety follow the
installation instructions carefully.
Do NOT connect the heater to a chimney serving another appliance.
Although the exterior of the heater may appear cool, contact with the unit may cause
burns; warn children and others of the possibility of injury should they touch the heater.
Do NOT dry clothing or unseasoned wood directly in contact with the heater.
Keep all household combustible materials at least 600mm away from front of the heater.
This includes clothing, furniture, wood, newspaper, plastic, matches, etc.
DO NOT USE FLAMMABLE LIQUIDS OR AEROSOLS IN THE VICINITY OF
THIS APPLIANCE WHEN IT IS OPERATING.
Use caution when reloading with fuel. Do NOT attempt to load fuel into the heater
when the fire inside the stove is at or near its peak.
Do NOT burn large quantities of paper or combustible material that would create an
extremely hot/quick fire.
Do NOT burn highly coloured paper or brochures (junk mail).
USE ONLY DRY WOOD. AVOID BURNING WET OR GREEN WOOD.
THE USE OF SOME TYPES OF PRESERVATIVE TREATED WOOD AS A FUEL
CAN BE HAZARDOUS.
TIMBER TREATED WITH COPPER CHROMIUM AND ARSENIC TYPE
PRESERVATIVES WILL LEAVE TOXIC RESIDUES IN THE ASH, FIREBOX OR
WITHIN THE FLUE; TIMBER OFFCUTS FROM BUILDING CONSTRUCTION
WILL OFTEN CONTAIN BORIC SALTS. THE COMBUSTION OF THIS
MATERIAL OVER PROLONGED PERIODS CAN PRODUCE ADVERSE EFFECTS
ON REFACTORY LINING IN SOLID FUEL APPLIANCES. EMISSION OF
POISONOUS GASES CAN ALSO BE EXPERIENCED WITH THE BURNING OF
TREATED WOOD.
Driftwood with salt content will also cause rapid deterioration of the heater and should not
be used.

Aqualux AG Installation
4

Aqualux AG Installation
5
2. FLOOR PROTECTOR REQUIREMENTS
If the heater is to be placed on or within 500mm of a heat sensitive floor, an insulated
floor protector will be required.
The insulated floor protector needs to extend under the heater and in front of the door. See
dimensions for floor protector. Similarly a 200mm extension is required on each side of
the door opening unless the insulated floor protector forms an abutment with a wall or
heat shield at a lesser distance.
The heater and floor protector must be fixed to the floor for seismic restraint. Anchor
points are provided in the feet of the unit.
INSULATED FLOOR PROTECTOR CONSTRUCTION
An Insulated Floor Protector shall be a minimum thickness of 40mm , consisting of
20mm of an approved insulation material i.e. 2 sheets of 10mm micorboard or superlux,
10mm tile backing board and 10mm tiles or similar on the top surface. All joints on the
upper surface should be sealed to prevent spilt ash from contacting any heat-sensitive
material.
INSERT FLOOR PROTECTOR DIMENSIONS
WHEN BEING INSTALLED IN A MASONRY FIREPLACE
In a masonry fire place installation the standard front clearance from the fireplace breast
(brickwork, etc) can be reduced by increasing floor protector height.
AQUALUX INSERT
FLOOR PROTECTOR DEPTH
HEIGHT
Level 520
20 490
40 400
60 400(Min)
INBUILT FLOOR PROTECTOR DIMENSIONS
WHEN INSTALLING IN A BUILT IN FIRE CANOPY
(ZERO CLEARANCE BOX)
HEIGHT FROM FIRE BREAST
40mm 500

Aqualux AG Installation
6
3. BUILT IN FIRE CANOPY
A Built In Fire Canopy is required if the fire is not being installed into a
masonry fire place.
For Built In Fire Canopy installations see the following pages 6,7,8,9,10,11,12,13,14.

Aqualux AG Installation
7

Aqualux AG Installation
8
BUILT IN FIRE CANOPY INSTRUCTONS
FOR NON-MASONARY INSTALLATION

Aqualux AG Installation
9

Aqualux AG Installation
10

Aqualux AG Installation
11

Aqualux AG Installation
12

Aqualux AG Installation
13

Aqualux AG Installation
14

Aqualux AG Installation
15
Built In Fire Canopy Instructions

Aqualux AG Installation
16
4. PRE - INSTALLATION
(Refer diagram page 4)
In a Masonry Fireplace:
Before installing your Firenzo Insert it is important to check the condition of your
masonry chimney. Ensure any cracks are sealed, loose masonry repaired and the chimney
swept.
Check the dimensions of your fireplace opening. Firebricks may need to be removed and
the floor of the opening should be level using mortar if necessary.
Ensure any gaps between the chimney face and fireplace surround are sealed with heat
resistant material.
MANTEL – Masonry Fireplace
If the mantel shelf is of a combustible material there should be a minimum distance above
the top of the fascia of 400mm. This may be reduced if a deflector or heat shield is fitted
under the mantel.
MANTEL – using BUILT IN FIRE CANOPY
FORTE AQUALUX – Can NOT have a combustible mantel, however if the mantel is
made of a non heat sensitive material then the minimum distance above the top of the
fascia must be 500mm.
ATHENA AQUALUX – The minimum distance above the top of the fascia to a
combustible or non-combustible mantel is 500mm.
SIDE SURROUNDS – MASONRY & BUILT IN FIRE CANOPY
Clearance between the fascia and any wooden side surround must be 50mm providing the
timber protrudes no more than 100mm.
5. ASSEMBLY INSTRUCTIONS
1 Carefully remove all packaging.
2a If installation is into a MASONRY ENCLOSURE: Remove firebricks as necessary
to fit the firebox into the opening. The firebox front when installed must be flush with
the finished fireplace surround and on a level base of the same height as the finished
floor protector. This may be achieved by using a concrete mix to level the base.

Aqualux AG Installation
17
2b If installation is into a BUILT-IN CANOPY: Construct the canopy box as per page 7.
Ensure the holes for the wetback pipework are predrilled into the built-in canopy
following the instructions in the Aqualux Built-In Canopy conversion kit. Install into
framework following guides on pages 8-14 as applicable.
3 Slide the firebox into the opening so that the outer casing return folds are flush
with the finished fire surround.
4 DUE TO NEW ZEALAND BEING AN EARTHQUAKE PRONE COUNTRY, IT IS
IMPORTANT TO ANCHOR THE INSERT DOWN IN CASE OF EARTH
MOVEMENT. See diagram page 18 showing Typical Insert Installation.
5 Make pipework connections to the wetback following the guide in Section 6 Wetback
(page 19) and test.
When installed into Built-in Canopy ensure pipework is sealed as per the instructions
in the Aqualux Built-in Canopy conversion kit.
6 Install Flue as per instructions on page 20 and 21 if installing in a masonry fireplace
or page 8,9,10,11,12, 15 if using a Built-in fire canopy (zero clearance box).
7 Now that the firebox and flue are in position, place 25mm white kaowool blanket
(supplied) on top of casing.
8 As this fire sources its combustion air from the chimney cavity/enclosure, the fire
MUST be sealed around the front between the casing and the masonry or inbuilt
canopy. This is achieved by packing the yellow ISB insulation supplied between the
casing and the masonry or inbuilt canopy at the FRONT ONLY to maximum depth of
90mm.
UNDER NO CIRCUMSTANCES SHOULD THE AIRPORTS ON THE
SIDE OF THE HEATER BE RESTRICTED. Refer diagram page 18.
The fire sources its combustion air from the chimney cavity, not from the
room where the fire is installed. This ventilation air should be drawn down
the chimney cavity from the air gap set up when the top spacer bracket holds
the weather collar off from the outer flue casing enabling air to be drawn into
the chimney cavity. Failure to ensure this air supply will starve the fire of air
and lead to poor performance.
NOTE: In the case of some insert fires into existing masonry fireplaces it may be necessary
to install additional adventitious ventilation into the chimney cavity as per AS/NZ
2918 3.4.1.2 to assist air flow into the fire.. This ventilation should not be
taken/drawn from the room that the fire is installed in.
9 Assemble and fit the fascia as per instructions on page 22.

Aqualux AG Installation
18

Aqualux AG Installation
19
6. WETBACK
The Forte Aqualux AG & Athena Aqualux AG are fitted with a wetback to supplement
the hot water system.
WARNINGS:
DO NOT CONNECT TO AN UNVENTED HOT WATER SYSTEM.
DO NOT USE THIS FIRE WITHOUT THE WETBACK CONNECTED AND
WATER RUNNING THROUGH THE WETBACK.
Care must be taken to protect the wetback and associated pipework if being installed in a
hard water / corrosive water area. Damage caused to the wetback due to hard / corrosive
water will not be covered under manufacturer’s warranty.
INSTALLATION OF WETBACK PIPEWORK MUST ONLY BE CARRIED OUT BY
A COMPETENT PERSON IN ACCORDANCE WITH AS 3500.4.1 OR NZS 4603 AND
THE APPROPRIATE REQUIREMENTS OF ALL RELEVANT BUILDING CODES
AND BEST PRACTICES.
For best performance apply the following rules:
1. Keep it simple with the shortest and straightest possible pipe run.
2. The heater should be within 3 metres of the hot water cylinder, the closer the better.
3. The flow pipe from the heater to the cylinder must rise – the cylinder should be at
least 300 mm above the wetback outlet.
4. Use only 25mm flow and return pipes.
5. Where possible the pipes should be
insulated.
6. A pre-plumb pipe work jig is available to
assist in pre-piping of the wetback pipework to
the inlet connection points on the heater, within
the masonry enclosure. Please contact your
dealer for details.
7. If the wetback is being linked to a solar
and/or secondary heatsource system the
pipework arrangement must be installed
to the specific manufacturers instructions.

Aqualux AG Installation
20
7. INSERT FLUE SYSTEM
For Installation in a Masonry Fireplace
WARNING; The appliance and flue system
shall be installed in accordance with AS/NZS
2918:2001 and the appropriate requirements of
the relevant building code or codes.
1. Position heater in fireplace. Extend plumb
line from top of chimney; ensuring heater spigot
is in line with top of chimney. If not, flue pipe
offsets will be required.
2. Assemble flue pipes ensuring all seams are in
line and assembly is straight and tight with
crimped ends pointing downwards.
Secure flue pipes with at least 3 stainless steel
or monel rivets and seal.
3. Fasten chimney plate supplied onto the
chimney top. The chimney plate must be
weather sealed with silicone or mortar.
4. Install chimney liner on top of the chimney
plate.
5. Ensure flue pipe is extended over the
chimney liner by 180mm. Secure top spacer
bracket to the flue pipe and ensure slots fit
snugly inside the chimney liner.
6. Slide flashing cone over top of flue, until it
rests firmly over top spacer. Secure with pop
rivets or self tapping screws.
7. Fit anti-down draught cowl. Do not secure
as it must be removed for cleaning.
CAUTION: Mixing of flue system components from different sources or modifying the
dimensional specifications of components may result in hazardous conditions. Where such
action is considered the flue manufacturer should be consulted in the first instance.
Refer also to notes on page 21 regarding height of flue system outlet.