Flavel Rocco FCFL**RN3 User manual

Rocco
Model No. FCFL**RN3
LOG EFFECT CONVENTIONAL FLUE
ROO HEATER
Installation and aintenance Instructions
Hand these instructions to the user
odel No. FCFL**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 Flue & Chimney Suitability 4
1.3 Shelf position 5
1.4 Hearths 5
1.5 Installation to plastered wall surfaces 5
Section 2 Installation of Fire
2.1 Unpacking the combustion chamber 6
2.2 Preparing the combustion chamber opening (In studded wall) 7
2.3 Preparing the combustion chamber opening (In chimney breast) 8-9
2.4 Securing the fire to the opening 10
2.5 Installation of the gas supply 11
2.6 Removal & re-fitting of the glass frame 12
2.8 Connection of the flue liner and fitting of the draught diverter 13-14
2.9 Fitting of the flue terminal and fitting of the draught diverter 15
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the fuel bed logset 16-20
3.2 Making the gas connection & checking for gas tightness 20
3.3 Lighting the appliance 21-23
3.4 Removal & re-fitting the trim 23
3.5 Checking for clearance of combustion products 24
Section 4 aintenance
4.1 Removal of the burner assembly 25
4.2 Removal of the control valve 25-26
4.3 Removal of the ultrasonic reciever 26
4.4 Removal of the pilot assembly 26
4.5 Removal / Replacement of batteries in the Ultrasonic Receiver 27
4.6 Removal / Replacement of the handset battery 27
odel number FCFL**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 7977-1 : 2002 and the result is 49%.
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
INFOR ATION AND REQUIRE ENTS
1.0 APPLIANCE INFOR ATION
Main injector : (1 off) Bray Injector Cat 82 – size 420 (NG)
Pilot Type : Copreci ODS 21100 / 141
Max. Gross Heat Input : 6.9 kW
Min. Gross Heat Input : 3.5 kW
Gas Rate : 0.634 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 : 33.0 kg
Fig. 1
Top View of Combustion Side View of Combustion
Chamber Chamber
3
795 mm
727 mm
335 mm
375mm
Flue
pigot
138mm
515mm
560mm
138mm CR
335mm
167mm
Flat Face of Flue Termination
must be installed facing front
of product only.
Minimum 50mm
clearance required
around flue outlet
as shown by dotted
line

INSTALLATION REQUIRE ENTS
1.1 CONDITIONS OF INSTALLATION
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. BS 5871 Part 2 Installation of Inset Live Fuel Effect Gas Fires
2. BS 6891 Installation of Gas Pipework
3. BS 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. BS 1251 Open fire place components
5. BS 715 / BS EN 1856-2 Metal flue pipes for gas appliances
6. BS EN 1858 Clay Flue Blocks and Terminals
7. IS 813 : Domestic Gas Installation (Republic of Ireland)
No purpose made additional ventilation is normally required for this
appliance, when installed in G.B. When Installing in I.E. please consult
document I.S. 813 : Domestic Gas Installation, which is issued by the
National Standards Authority of Ireland. If installing in Northern Ireland,
please consult local building regulations. Any purpose made ventilation
must be checked periodically to ensure that it is free from obstruction.
1.2 FLUE AND CHI NEY SUITABILITY
This appliance is designed for use with conventional brick built or lined chimneys
and fabricated flues and metal flue boxes conforming to BS 715 / BS EN 1856-2.
All flues must conform to the following minimum dimensions.
inimum diameter of circular flues 125 mm
inimum effective height of all flue types 4 metres
ENSURE THAT IF INSTALLING THIS PRODUCT INTO A BRICK BUILT CHIMNEY, THE CHIMNEY HAS
BEEN FULLY SWEPT PRIOR TO PROCEEDING WITH THE INSTALLATION. IT IS RECOMMENDED
IN PROPERTIES WITH LARGE CHIMNEY CROSS-SECTIONAL AREA’S THAT A 125MM
DIAMETER FLUE LINER IS FITTED. IF THE CHIMNEY HEIGHT EXCEEDS 10 METRES ON AN
EXTERNAL WALL OR 12 METRES ON AN INTERNAL WALL, THE CHIMNEY MUST BE FULLY
LINED. AS WITH ALL HOLE IN THE WALL TYPE ROOM HEATERS, PLEASE ENSURE THAT YOU
ARE MEASURING THE EFFECTIVE FLUE HEIGHT FROM THE TOP OF THE COMBUSTION
CHAMBER, NOT THE BASE OF THE CHIMNEY
Safe clearance of products must always be checked by carrying out a smoke match test as described on
page 24.
4

1.3 SHELF 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.
1.4 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
1.5 INSTALLATION TO PLASTERED WALL 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. 2 below
The mounting frame supplied must always be used.
Fig. 2
5
Combustion Chamber
Opening in Studded all or
Existing Chimney Breast
750mm
540mm
Minimum 50mm of
material to be removed
all round perimeter of
combustion chamber
and replaced with
marble, granite or other
non-combustible
material to create a
sealing area. ecure
combustion chamber via
four off mounting holes
in mounting frame

SECTION 2
INSTALLATION OF FIRE
2.1 UNPACKING THE CO BUSTION CHA BER
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 CIRCU STANCES USE THIS APPLIANCE IF THE
GLASS PANEL IS BROKEN OR NOT SECURELY FIXED TO THE FIREBOX.
Packing Check List
1 off Combustion Chamber & Glass Frame Assembly
1 off Trim / Mounting Frame (packed in front section of combustion chamber
pack)
1 off Boxed ceramic fuel-bed set (packed inside combustion chamber)
1 off 125mm flue spigot adaptor (packed inside combustion chamber)
1 off Flue terminal assembly (packed inside combustion chamber)
1 off Draught diverter assembly (packed inside combustion chamber)
1 off Installation Instruction Manual
1 off User Instruction Manual
1 off Length of foil tape
1 off Handset & 1 off 9V Battery
1 off Loose Items pack – containing :-
4 off No. 12 x 40mm Screws
4 off Rawlplugs
4 off AA Batteries
I PORTANT NOTE BEFORE PROCEEDING WITH THE INSTALLATION
This product requires a minimum effective flue height of 4.0 metres of minimum
circular cross-sectional area 125mm. If installing the product into a 225mm x
225mm brick chimney, THE CHIMNEY SOUNDNESS MUST BE CHEC ED BY
TESTING prior to a decision being made on whether the chimney requires lining.
If the flue height is greater than 10 metres on an external wall or 12 metres on an
internal wall then a flue liner must be fitted even if the chimney integrity is ok.
Please check the chimney height and integrity prior to proceeding with the
installation, to establish if a chimney liner is required. Any flue pipe should
conform to BS 715 / BS EN 1856-2 (Metal flue pipes for gas appliances).
When you have decided upon if the product requires the fitting of a flue
liner, proceed with the creation of the correct sized builders opening or
studwork installation of the product as per sections 2.2 or 2.3
6

2.2 PREPARATION OF THE CO BUSTION CHA BER OPENING
(INTO STUDDED WALL) USING A 125 FLUE LINER.
All combustible parts of the studwork must be set at the distances as shown below
in Fig. 3 & 4.
7
Minimum 50mm at sides
Minimum 50mm at rear
Combustion Chamber
Dimension “A”
Minimum Width
750mm
Maximum Width
765mm
Dim “A”
Dim “B”
Dimension “B”
Minimum Height
520mm
Maximum Height
540mm
Dim “C”
Dimension “C”
Minimum Depth
340mm
Fig. 3
Fig. 4
A minimum clearance of
100mm is required above
the top of the draught
diverter to combustible
surfaces
Minimum 125mm flue liner required
125mm diameter minimum
flue liner required
20mm Mounting Frame
MINIMUM HEIGHT FROM
FLOOR LEVEL TO
BOTTOM OF OPENING IS
150MM

2.3 PREPARATION OF THE CO BUSTION CHA BER OPENING
(INTO EXISTING CHI NEY BREAST)
An opening should be constructed to the following dimensions in the existing
chimney breast. See fig. 5 below
Fig. 5
NOTE : Please ensure that access holes are cut into either the sides or area
above the lintel to allow access to the flue pipe connection if using a flue liner.
Such access holes are also advantageous in installations where a flue liner is not
required as they provide access for servicing purposes.
If installing without a flue liner, please ensure that sufficient depth is available in
the opening to collect a minimum volumetric area of 12 litres (0.012m3) of flue
debris.
Refer to Fig. 1 on page three for dimensions of the flue outlet.
CHECK ANY LOAD BEARING STRUCTURAL ITE S ARE NOT
AFFECTED BY THE INSTALLATION OF THE PRODUCT. SEE FIG 6
OVERPAGE.
8
Minimum Width 750mm
Maximum Width 765mm
Minimum Height 520mm
Maximum Height 540mm
Minimum Depth 335mm
with liner, 365mm without
liner
Lintle must
project 150mm
either side of the
opening if
cutting into an
existing chimney
breast

Fig. 6
If fitting without a flue liner, ensure a minimum clearance of 50mm is available
around the semi- circular section of the flue termination to any surface within the
chimney structure. - See page 3, Fig. 1 for more information on clearance to the
flue termination.
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. 6 above. 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.
9
400mm interactive area
600mm load triangle
The 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

10
2.4 SECURING THE CO BUSTION CHA BER TO THE OPENING
a) The combustion chamber must be secured to the opening via the four
off screw and rawlplugs provided. Fig. 7 below shows the hole centres
in the mounting flanges of the combustion chamber.
Fig. 7
b) DO NOT SECURE THE COMBUSTION INTO THE OPENING AT THIS
POINT AS ACCESS WILL STILL BE REQUIRED TO RUN THE GAS
SUPPLY PIPEWOR AS DETAILED IN SECTION 2.5
Fig. 8
448mm
779mm
4 holes in combustion
chamber mounting flange
for securing to the opening

2.5 INSTALLATION OF THE GAS SUPPLY (INTO STUDDED WALL OR
EXISTING CHI NEY 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. 9, 10 &
11 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 upply entering from L/H/
Combustion Chamber
Gas upply 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. 9
Fig. 10
Combustion Chamber
Fig. 11
Gas upply entering from R/H/

2.6 RE OVING / RE-FITTING THE GLASS FRA E ASSE BLY
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. 12 below.
Fig. 12
b) The assembly is then secured to the bottom of the combustion chamber
by the two hinge clamp brackets as shown below in Fig. 13. These
are clamped together to form the seal between the glass frame
assembly and the combustion chamber.
Fig. 13
NOTE : Always ensure that a consistent seal between the combustion
chamber and the glass frame is achieved.
Glass Frame Assembly
locates over lip on top of
combustion chamber lid, and
drops onto flange as shown.
To remove, unclip base clips
as shown in Fig. 12 and lift
clear.
denotes correct
final position of
glass frame.
Combustion
Chamber
12

2.7 CONNECTION OF THE FLEXIBLE FLUE LINER (IF FITTED)
a) If fitting with a 5” / 125mm flue liner, ensure the liner has been
connected and securely fixed at the top of the chimney in accordance
with the manufacturers instructions. Feed or align the flexible flue liner
through the hole in the top of the combustion chamber The flexible liner
should be then fitted to the 5” / 125mm spigot adaptor as shown below
in Fig. 14
Fig. 14
b) Re-fit the 5” / 125mm flue spigot adaptor into the top of the combustion
chamber, and secure with the four M4 screws as shown below in Fig.
15.
Fig. 15
13
Fit flexible flue liner to
the 5” / 125mm spigot
adaptor via 3 off
retaining clips as
shown
Refit 4 off M4
crews

c) Re-fit the draught diverter and secure with the five off M4 screws as
shown below in Fig. 16
Fig. 16
If fitting without a flue liner, please proceed to section 2.8 overpage
I PORTANT NOTE :
ENSURE THAT THE DRAUGHT DIVERTER HAS THE 3 OFF SCREWS
FITTED AT THE FRONT EDGE NEAREST THE GLASS PANEL. THIS WILL
ENSURE THAT THE DRAUGHT DIVERTER IS FITTED IN THE CORRECT
ORIENTATION IN THE CO BUSTION CHA BER.
IT IS VERY I PORTANT TO THE SAFETY AND PERFOR ANCE
OF THE PRODUCT THAT THE DRAUGHT DIVERTER IS RE-FITTED.
DO NOT CONTINUE WITH THE CO ISSIONING OF THE PRODUCT
UNTIL THIS CO PONENT IS IN THE CORRECT POSITION.
IF A FLUE LINER HAS BEEN USED THROUGHOUT THE ENTIRE LENGTH
OF THE CHI NEY, THE LABEL ATTACHED TO THE GAS INLET ELBOW
REGARDING INSTALLATION OF PRODUCTS WITHOUT A FLUE LINER
CAN NOW BE RE OVED AND DISCARDED.
14
Refit
5 off M4
crews

2.8 CONNECTION OF THE FLUE TER INAL AND RE-FITTING THE
DRAUGHT DIVERTER.
a) If fitting without a flue liner, into a chimney that is has had it’s
soundness assured by testing, and is less than 10 metres in
height on an external wall or 12 metres on an internal wall, then the
appliance can be fitted with the flue terminal as supplied. The
terminal is secured with 4 off M4 screws. See Fig. 17 below.
b) Re-fit the draught diverter and secure with the five M4 screws as
shown below in Fig. 18, ensuring the edge with 3 screw location points
is at the front of the product.
Fig. 17 Fig. 18
15
I PORTANT NOTE :
ENSURE THAT THE DRAUGHT DIVERTER HAS THE 3 OFF SCREWS
FITTED AT THE FRONT EDGE NEAREST THE GLASS PANEL. THIS WILL
ENSURE THAT THE DRAUGHT DIVERTER IS FITTED IN THE CORRECT
ORIENTATION IN THE CO BUSTION CHA BER.
IT IS VERY I PORTANT TO THE SAFETY AND PERFOR ANCE
OF THE PRODUCT THAT THE DRAUGHT DIVERTER IS RE-FITTED.
DO NOT CONTINUE WITH THE CO ISSIONING OF THE PRODUCT
UNTIL THIS CO PONENT IS IN THE CORRECT POSITION.
ENSURE THE LABEL THAT SPECIFIES THE PRODUCT HAS BEEN
INSTALLED WITHOUT A FLUE LINER IS NOW CORRECTLY FILLED IN
WITH THE INSTALLERS DETAILS. THE LABEL IS FITTED TO THE GAS
INLET ELBOW AND UST BE LEFT IN POSITION FOLLOWING
CO ISIONING OF THE PRODUCT.
Refit 5 off M4
crews
Refit 4 off M4
crews
NOTE : THE FLAT FACE OF THE
FLUE TERMINATION MU T BE
FITTED FACING TOWARD THE
FRONT OF THE PRODUCT -
EE FIG. 1 ON PAGE 3.

SECTION 3
INSTALLATION OF FIRE
3.1 FITTING THE FUEL-BED LOGSET
a) The gravel material should then be first layed around the base of the
combustion chamber as shown below in Fig. 19, leaving the rear
section as shown to allow the fitting of Log “A”
Fig. 19
b) Place the largest Log “A” centrally onto the fuel-bed support behind the
burner flame strip. Ensure that the fuel-bed Log “A” is located centrally
in the firebox, and that the front edge is parallel with the rear face of the
burner flame strip as shown below in Fig. 20.
Fig. 20
Fuel-bed
Log “A” to be
fitted behind
burner flame
strip
16
A

c) Fit Log “B” into position on left hand side of the fuel-bed base log “A”as
shown below in Fig. 21, using the groove in Log “A” as a guide for
placement.
Fig. 21
d) Fit Log “C” into position on left hand side of the fuel-bed base log “A”as
shown below in Fig. 22, using the groove in Log “A” as a guide for
placement.
Fig. 22
17
B
C

d) Fit Log “D” into position on left hand side of the fuel-bed base log “A”as
shown below in Fig. 23, using the groove in Log “A” as a guide for
placement.
Fig. 23
e) Fit Log “E” into position at centre of the fuel-bed base log “A”as
shown below in Fig. 24, using the groove in the centre of Log “A” as a
guide for placement.
Fig. 24
18
D
E

f) Fit Log “F” into position at right hand side of centre of the fuel-bed base
log “A”as shown below in Fig. 25, using the groove in Log “A” as a
guide for placement.
Fig. 25
g) Fit Log “G” into position at right hand side of the fuel-bed base log “A”as
shown below in Fig. 26, using the raised section in the base log as a
guide for position.
Fig. 26
I PORTANT NOTE
HAVING FITTED THE GRAVEL ATERIAL IN THE BASE OF THE
CO BUSTION CHA BER, ENSURE THAT NONE OF IT IS ON THE BURNER
FLA E STRIP OR IN THE PILOT ASSE BLY. IF ATERIAL IS OBSERVED
VISUALLY ON THESE CO PONENTS, RE OVE THE FUEL-BED LOGSET,
RE OVE THE GRAVEL ATERIAL FRO THE BURNER AND OR PILOT AND
RE-FIT THE LOGS AS DETAILED IN SECTION 3.1 ABOVE.
19
F
G

Warning : Use only the logs supplied with the fire. When replacing the
logs remove the old logs and discard them. Fit a complete set of logs of the
correct type. Do not fit additional logs or any logs other than a genuine
replacement set.
This appliance uses fuel effect pieces containing Refractory Ceramic Fibres (R.C.F.), which are
man-made vitreous silicate fibres. Excessive exposure to these materials may cause temporary
irritation to eyes, skin and respiratory tract. Consequently, it makes sense to take care when han-
dling these articles to ensure that the release of dust is kept to a minimum. To ensure that the
release of fibres from these R.C.F. articles is kept to a minimum, during installation & servicing we
recommend that you use a HEPA filtered vacuum to remove any dust and soot accumulated in and
around the fire, before and after working on the fire. When replacing these articles we recommend
that the replaced items are not broken up, but are sealed within a heavy duty polythene bag,
clearly labelled as “RCF waste”. This is not classified as “hazardous waste” and may be disposed
of at a tipping site licensed for the disposal of industrial waste. Protective clothing is not required
when handling these arrticles, but we do recommend you follow the normal hygiene rules of not
smoking, eating or drinking in the work area, and always wash your hands before eating or
drinking.
This appliance does not contain any component manufactured from
asbestos or asbestos related products.
Refit the glass frame as detailed in section 2.6 (page 12), then light the appliance as detailed in section
3.3
3.2 AKING THE GAS CONNECTION & CHECKING FOR GAS
TIGHTNESS
a) Before making the final gas connection, thoroughly purge the gas
supply pipework to remove all foreign matter, otherwise serious
damage may be caused to the gas control valve on the fire.
Failure to purge the gas supply will invalidate the guarantee.
b) The gas connection should be made to the appliance inlet elbow to
using 8mm rigid tubing.
c) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
d) Turn on the main gas supply and carry out a gas tightness test.
20