Flavel Rocco FBFL**RN3 User manual

Rocco
Model No. FBFL**RN3
OG EFFECT BA ANCED F UE ROOM HEATER
Installation and Maintenance Instructions
Hand these instructions to the user
Model No. FBF **RN3 is for use on Natural Gas (G20) at a supply pressure
of 20 mbar in G.B. / I.E.
** Denotes trim & colour variant

CONTENTS
PAGE
Section 1 Information and Requirements
1.0 Appliance information 3
1.1 Conditions of installation 4
1.2 Fireplace surround & suitability 4
1.3 Flue terminal position 5
1.4 Shelf position 6
1.5 Hearths 6
1.6 Installation to plastered wall surfaces 6
Section 2 Installation of Fire
2.1 Unpacking the combustion chamber 7
2.2 Preparing the combustion chamber opening (In studded wall) 8
2.3 Preparing the combustion chamber opening (In chimney breast) 9-10
2.4 Installation of the gas supply 11
2.5 Specifying the flue system & components 12-14
2.6 Preparation of the wall 14
2.7 Preparation of the flue hole 15
2.8 Fitting the starter pipe 15-16
2.9 Fitting the flue pipes together 17
2.10 Fitting the flue terminal 18
2.11 Fitting the flue terminal guard 19
2.12 Removal & re-fitting of the glass frame 20
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the fuel bed logset 21-25
3.2 Making the gas conection & checking for gas tightness 26
3.3 Lighting the appliance 26-28
3.4 Removal & re-fitting the trim 29
Section 4 Maintenance
4.1 Removal of the burner assembly 30
4.2 Removal of the control valve 30-31
4.3 Removal of the ultrasonic reciever 31
4.4 Removal of the pilot assembly 31-32
4.5 Removal / Replacement of batteries in the Ultrasonic Receiver 32
4.6 Removal / Replacement of the handset battery 32
Model number FBF **RN3 manufactured by:-
BFM Europe Ltd, Trentham Lakes, Stoke-on-Trent, Staffordshire, ST4 4TJ
Appliance Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS EN 613 : 2001 and the result is 74%. 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 Advantica. The efficiency value may be used in
the U Government’s Standard Assessment Procedure (SAP) for energy rating of
dwellings.
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APP IANCE INFORMATION
Main injector : (1 off) Bray Injector Cat 82 – size 480 (NG)
Pilot Type : S.I.T. 140 Series NG – size 27
Max. Gross Heat Input : 7.5kW
Min. Gross Heat Input : 3.5 kW
Gas Rate : 0.691 m3/hr (High)
0.325 m3/hr (Low)
Cold Pressure : G20 20.0+/-1.0 mbar (8.0 +/- 0.4 in w.g.)
Ignition : Integral to gas valve
Electrode Spark Gap : 4.0mm
Packed Weight Combustion Chamber : 40.0 kg (Pack 1 of 1)
Packed Weight Flue Terminal Pack : 16.0 kg (Pack 2 of 2)
Fig 1
Top View of Combustion Side View of Combustion
Chamber Chamber
3
795 mm
728 mm
370 mm
364mm
150mm
Diameter
138mm
75mm
550mm
465mm
138mm CRS
370mm
436mm
26mm

INSTA ATION REQUIREMENTS
1.1 CONDITIONS OF INSTA ATION
It is the law that all gas appliances are installed only by a GAS SAFE Registered
Installer, in accordance with these installation instructions and the Gas Safety
(Installation and Use) Regulations 1998 as amended. Failure to install appliances
correctly could lead to prosecution. It is in your own interest and that of safety to
comply with the law.
The installation must also be in accordance with all relevant parts of the Local and
National Building Regulations where appropriate, the Building Regulations
(Scotland Consolidation) issued by the Scottish Development Department, and all
applicable requirements of the following British Standard Code of Practice.
1. B.S. 5871 Part 1 Installation of Gas Fires
2. B.S. 6891 Installation of Gas Pipework
3. B.S. 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. I.S 813 : 1996 Domestic Gas Installation, issued by the National Standards
Authority of Ireland.
1.2 FIREP ACE / SURROUND SUITABI ITY
The fire must only be installed on a hearth it must not be installed directly onto
carpet or other combustible floor materials.
The fire is suitable for fitting to non-combustible fire place surrounds and propri-
etary fire place surrounds with a temperature rating of at least 150oc.
If a heating appliance is fitted directly against a wall without the use of a fire
surround or fire place all combustible material must be removed from behind
the trim. Soft wall coverings such as blown vinyl, wall paper etc. could be
affected by the rising hot air and scorching and/or discoloration may result.
Due consideration should be made to this when installing or decorating.
4

1.3 F UE TERMINA POSITION
The minimum acceptable dimensions from the flue terminal to obstructions
and ventilation openings are shown below and listed in the table
It is important that the position of the flue allows the free passage of air
across it at all times. The minimum acceptable space from the flue terminal
to obstructions and ventilation openings are specified below (Fig. 2)
Fig. 2
DIMENSION TERMINA POSITION MINIMUM DIMENSION
A Directly below an opening, air brick, 300mm (12in)
opening window
B Above an opening, air brick, 300mm (12in)
opening window
C Horizontally to an opening, air brick,
opening window etc.
D Below gutters, soil pipes or drain pipes 300mm (12in)
E Below eaves 300mm (12in)
F Below balconies or car port roof 600mm (12in)
G From a vertical drain pipe or soil pipe 300mm (12in)
H From an internal or external corner 600mm (24in)
I Above ground roof or balcony level 300mm (12in)
J From a surface facing the terminal 600mm (24in)
K From a terminal facing the terminal 600mm (24in)
From an opening in the car port 1200m (48in)
M Vertically from a terminal on the same wall 1500mm(59in)
N Horizontally from a terminal on the 300mm (12in)
same Wall
O NOT APP ICAB E N/A
P NOT APP ICAB E N/A
Q NOT APP ICAB E N/A
5

1.4 SHE F POSITION
The fire may be fitted below a combustible shelf providing there is a minimum
distance of 300mm above the top of the fire and the shelf does not project more
than 150mm. If the shelf overhangs more than 150mm the distance between the
fire and the shelf must be increased by 15mm for every 25mm of additional
overhang over 150mm.
1.5 HEARTHS
This appliance does not require the fitting of a hearth that projects in front of it
when installed into a recess in either an existing chimney breast or a studded wall.
The appliance must however stand on a non-combustible base that is a minimum
thickness of 12mm
1.6 INSTA ATION TO P ASTERED WA SURFACES
If installing to a plastered wall, all material must be removed from the 50mm area
surrounding the combustion chamber opening, and replaced with non-combustible
material, such as marble or granite, to prevent plaster cracking. See Fig. 3 below
Fig. 3
6
Combustion Chamber
Opening in Studded Wall or
Existing Chimney Breast
730mm
540mm
Minimum 50mm
of material to be
removed all
round perimeter
of combustion
chamber and
repalced with
marble, granite
or other non-
combustible
material

SECTION 2
INSTA ATION OF FIRE
2.1 UNPACKING THE COMBUSTION CHAMBER
Carefully lift the combustion chamber out of the carton. Remove the loose item
packaging carefully from the pack. Check the contents as listed :-
DO NOT UNDER ANY CIRCUMSTANCES USE THIS APP IANCE IF THE
G ASS PANE IS BROKEN OR NOT SECURE Y FIXED TO THE FIREBOX.
Packing Check List
Pack 1 of 2 - Combustion Chamber Pack
1 off Combustion Chamber & Glass Frame Assembly
1 off Trim (packed in front section of combustion chamber pack)
1 off Boxed ceramic fuel-bed set (packed inside combustion chamber)
1 off Installation Instruction Manual
1 off User Instruction Manual
1 off Flue Terminal Guard
1 off Loose Items pack – containing :- 6 off M6 wingnuts
4 off No. 12 x 40mm Screws
4 off Rawlplugs
Carefully lift the flue kit components out of the carton. Remove the loose item
packaging carefully from the pack. Check the contents as listed :-
Pack 2 of 2 - Flue System Pack
1 off Flue Terminal
1 off 150mm Starter Pipe
1 off *Telescopic Flue Pipe - supplied in two seperate sections
1 off 90 degree elbow
3 off Pipe Clips
*These two sections of the telescopic need to be assembled by the
installer to form the 250mm to 410mm telescopic piece.
7

2.2 PREPARATION OF THE COMBUSTION CHAMBER OPENING
(INTO STUDDED WA )
All combustible parts of the studwork must be set at the distances as shown below
in Fig. 4 & 5.
Refer to Fig. 1 on page three for dimensions of the flue outlet.
8
Minimum 50mm at sides
Minimum 50mm at rear
Combustion Chamber
Dimension “A”
Minimum Width
730mm
Maximum Width
780mm
Dim “A”
Dim “B”
Dimension “B”
Minimum Height
540mm
Dim “C”
Dimension “C”
Minimum Depth
380mm
Fig. 4
Fig. 5
A minimum clearance of
100mm is required above
the top of the flue pipe to
combustible surfaces
IMPORTANT
ENSURE PLATFORM FOR
SUPPORTING PRODUCT
IS APPROXIMATEL
30MM BELOW THE
BOTTOM OF THE
OPENING TO PREVENT A
GAP AT BOTTOM OF THE
TRIM

2.3 PREPARATION OF THE COMBUSTION CHAMBER OPENING
(INTO EXISTING CHIMNEY BREAST)
An opening should be constructed to the following dimensions in the existing
chimney breast.
Fig. 8
The opening needs to be sufficient to accomodate the combustion chamber. To
support the wall above the opening, a suitable lintel must be inserted across the
top of the opening. The lintel could be either pre-cast concrete or steel - Catnic
CN52 or CN 46 could be used, depending upon the inner wall thickness. Before
proceeding with the installation of the fire, an assessment of the area immediately
above the fire is required, see Fig. 9 overpage. If there is no existing openings
within either triangle, proceed with forming the opening. However, if opening or
beams occur within either triangle, then you should seek specialist advice from a
structural engineer or consider relocating the proposed position of the firebox.
NOTE : Please ensure that suitable cut outs in the sides and front face of the
chimney breast are implemented for fixing of the flue pipe, and for future
servicing.
9
Minimum Width 730mm
Maximum Width 780mm
Minimum Height 540mm
Minimum Depth 380mm
Lintle must
project 150mm
either side of the
opening if
cutting into an
existing chimney
breast
IMPORTANT
ENSURE PLATFORM FOR
SUPPORTING PRODUCT
IS APPROXIMATEL 30MM
BELOW THE BOTTOM OF
THE OPENING TO PRE-
VENT A GAP AT BOTTOM
OF THE TRIM

Fig. 9
10
400mm interactive area
600mm load triangle
he Interactive Zone -
Openings, beams or joists within
this area need to be assessed.
Load triangle - No beam or
opening permissible within this
area
Lintel
e.g. 750mm x 75mm
Proposed Opening in
Chimney Breast
Minimum 200mm
Flue Pipe
Installation
Access
150mm
IMPORTANT
ENSURE PLATFORM FOR
SUPPORTING PRODUCT IS
APPROXIMATEL 30MM
BELOW THE BOTTOM OF
THE OPENING TO PRE-
VENT A GAP AT BOTTOM
OF THE TRIM

2.4 INSTA ATION OF THE GAS SUPP Y (INTO STUDDED WA OR
EXISTING CHIMNEY BREAST)
Before installing the combustion chamber, decide from which side or if a rear
connection to the gas supply is required. Plan the pipe run to enter the below the
firebox from the left, right or rear and connect to the inlet elbow. See Fig. 10, 11 &
12 below.
Note : Before breaking into the gas supply a gas tightness test should be
carried out to establish that the existing pipework is
sound.
11
Combustion Chamber
Gas Supply entering from L/H/S
Combustion Chamber
Gas Supply entering from Rear of Combustion Chamber
Outer
Cavity Wall or
rear face of
studwork
Ensure if bringing gas
supply through side or rear
of a chimney breast that the
pipe is sleeved and sealed
with a suitable flexible, non
setting compound
Fig. 10
Fig. 11
Combustion Chamber
Fig. 12
Gas Supply entering from R/H/S

2.5 SPECIFYING THE F UE SYSTEM & ASSOCIATED COMPONENTS
This product requires a minimum vertical flue length of 150mm (6 inch).
The horizontal length can then be extended up to a maximum of 1600mm, giving a
total depth from mounting flange to outer wall of 2000mm.
The standard flue kit supplied with the product comprises the following
components :-
1off Flue Terminal
1off Flue Terminal Guard
1off 150mm Starter Pipe
1off 250mm Minimum to 410mm Maximum Telescopic Flue Pipe
1off 90 degree elbow 3 off pipe clips
This kit comprises the components required to fit the appliance into a studded wall
or a chimney breast with a maximum depth of 880mm (From Mounting Flange of
Combustion Chamber to outer face of wall) The main flue pipe section is a
telescopic item which allows for a variation in depth of 160mm minimum to
maximum length (250mm to 410mm). See Fig. 13 below.
Fig. 13
12
Minimum
Wall
Thickness
Excluding
Flue Terminal
320mm
Flue erminal Length
200mm
Maximum Wall Thickness
Excluding Flue Terminal
410mm
Flue erminal
Length 200mm
90 Degree Elbow
150mm
Starter Pipe
90 Degree Elbow
150mm
Starter Pipe
elescopic Flue Section
elescopic Flue Section

In instances where a large depth cavity wall, chimney breast is encountered, or if
the installation requires a flue termination to the left or right hand of the
combustion chamber, the overall length from the centre of the flue spigot can be
increased up to 1600mm as shown below in Fig. 14
Fig. 14
In installation’s where components are required that exceed the limitations of the
components supplied with the standard kit, extra lengths of flue pipe are available
from BFM Europe Ltd. The lengths available and part no’s are shown below.
B-83970 1000mm Flue Length Section
B-83980 500mm Flue Length Section
B-83990 250mm Flue Length Section
B-84000 150mm Flue Length Section
Always ensure that the solid section is fitted to the elbow when installing
extra sections, followed by the telescopic section as supplied in the
standard flue kit, this will allow for differences in cavity wall depth to be
allowed for. See Fig. 15 overpage
13
1600mm Maximum
1600mm Maximum
1600mm
Maximum
Combustion Chamber
2000mm
Maximum

Fig. 15
2.6 PREPARATION OF THE WA / MOUNTING
The appliance and flue pipes must be installed at right angles to the mounting
wall. The appliance itself should be installed vertically against a flat wall. Where
an uneven wall surface is found, appropriate action should be taken to ensure that
the appliance is not stressed or does not distort when installed.
Ensure that the floor surface onto which the appliance is mounted onto is flat.
The minimum height from the mounting base to the centre of the flue is shown on
below in Fig. 16.
NOTE : Adjustable feet are fitted to the combustion chamber to allow fine tuning of
it’s positioning
Fig. 16
14
Additional Flue
Length e.g. 1000mm to
be fitted onto elbow
before telescopic
section is fitted, to take
into account
variation in wall cavity
depths
250mm to
410mm
elescopic
Section
90 degree
elbow
150mm Starter Pipe
Flue
erminal
Combustion
Chamber
900mm to
CRS of
Flue Pipe
Elbow
150mm Starter Pipe
A minimum clearance of
100mm is required above the
top of the flue pipe to
combustible surfaces

2.7 PREPARATION OF THE F UE HO E
a) Mark the position of the centre of the flue on the inner wall. (See Fig.
16 on previous page for position).
b) Cut hole for outer flue pipe. There are two possible methods to achieve
this, either core drill or via hammer and chisel.
c) To core drill, proceed as follows :-
Drill a pilot hole through the wall, in position as specified in figure 16 on
previous page.
Using a 6” core drill, drill the flue hole.
To Hammer and chisel, proceed as follows :-
Mark the position of the centre of the flue pipe as specified in figure 16.
Mark the position of the hole around this point.
Chisel out the area as marked on the wall.
We then recommend that a cardboard cylinder is placed around the flue pipe and
inserted in the chiselled out hole whilst making good.
NOTE :- If the appliance is to be installed into a building under
construction, it is recommended that a non-corrosive metal tube of 6”
diameter be inserted into the position of the hole as specified on page 16.
2.8 FITTING THE STARTER PIPE TO THE APP IANCE
a) Place gasket on top of the combustion chamber as shown below in Fig.
17
Fig. 17
15

b) The starter pipe is attached to the appliance by placing it over the spigot
on the combustion chamber and locating the mounting flange over the
weld studs that protrude from the top panel on the combustion chamber.
(See Fig. 18 below)
Fig. 18
c) When the starter pipe is located, tighten the 6 off wingnuts (supplied in
loose items pack) to seal the starter pipe to the combustion chamber.
(See Fig. 19 below)
Fig. 19
d) Fit the 90 degree elbow in the required direction of the flue pipe (L/H,
R/H or to the rear), and secure to the starter pipe with the clamps as
shown in section 2.9.
16

2.9 FITTING THE F UE PIPES TOGETHER
a) The flue pipes are located by pushing the sections together and
clamping using the clamps provided. As with all balanced flue
appliances ensure that the flue sections are fitted together horizontally.
b) The clamps are fitted together as shown below in Fig. 20 & 21
Fig. 20
Fig. 21
17

2.10 FITTING THE F UE TERMINA
a) The flue terminal locates over the telescopic flue section and is clamped
as per the other flue sections. The flue terminal must not protrude out
of the wall further than 150mm. This is indicated by the ridge on the
terminal itself. Failure to comply with this request will result in poor
performance of the product during adverse weather conditions.
See fig. 22 below for correct positioning of the flue terminal.
Fig. 22
18
Inner Cavity Wall Outer Cavity Wall
Correct Position of
Flue erminal
Flue terminal shown in correct
position with inlet area flush with
external wall
Inner Cavity Wall Outer Cavity Wall
Flue terminal shown in an incorrect
position, protruding beyond the
external wall
In-Correct Position of
Flue erminal
Ensure flue
pipes are
sealed to
inner and
outer cavity
and gap
around
terminal are
sealed

2.11 FITTING THE TERMINA GUARD
With the flue terminal in position, place the terminal guard over the top of the flue
terminal and mark the position of the holes on the outer wall. Remove the terminal
guard and drill the 4 off 6 mm holes. Insert the raw plugs into the drilled holes,
replace the terminal guard over the top of the flue terminal and attach to the wall
using the No.12 x 40mm screws provided with the terminal guard. See Fig. 23
below.
Fig. 23
NOTE : In England & Wales, the building regulations require that a terminal
guard should be fitted if the terminal could come into contact with people
near the building or be subject to damage. BFM Europe td. also
recommend the fitting of a flue terminal guard where regulations do not
demand that it be fitted. A suitable flue terminal guard is supplied with the
appliance.
19

2.12 REMOVING / RE-FITTING THE G ASS FRAME ASSEMB Y
a) The glass frame is held in position by hooking the top flange over the
combustion chamber opening at the top as shown in Fig. 24 below.
Fig. 24
b) The assembly is then secured to the bottom of the combustion chamber
by the two hinge clamp brackets as shown below in Fig. 25. These are
clamped together to form the seal between the glass frame assembly
and the combustion chamber.
Fig. 25
NOTE : Always ensure that a consistent seal between the combustion
chamber and the glass frame is achieved.
20
Glass Frame Assembly
locates over lip on top of
combustion chamber lid, and
drops onto flange as shown.
o remove, unclip base clips
as shown in Fig. 20 and lift
clear.
denotes correct
final position of
glass frame.
Combustion
Chamber