Flavel Rocco HE FPHL RN2 Series Mounting instructions

Rocco HE
Model No. FPHL**RN2
HIGH EFFICIENCY LOG EFFECT ROOM HEATER
Installation, Maintenance & User Instructions
Hand these instructions to the user
Model No. FPHL**RN2 is for use on Natural Gas (G20) at a supply pressure
of 20 mbar in G.B. / I.E.
** Denotes trim & colour variant

Information Requirements for Commission Regulation (EU) 2015/1188
Model Identifier FPHL**RN2
Indirect Heating Functionality No
Direct Heat Output 3.6kW
Indirect Heat Output Not Applicable
Fuel Natural Gas (G20)
NOx Emissions 130mg/kWh
Nominal Heat Output 3.6kW
Minimum Heat Output (Indicative, all models) 1.5kW
Useful Efficiency at Nominal Heat Output 73.9%
Useful Efficiency at Minimum Heat Output (Indicative) 50.0%
Auxilliary Power Consumption at Nominal Heat Output 0.000001kW
Auxilliary Power Consumption at Minimum Output 0.000001kW
Auxilliary Power Consumption at Standby Mode 0.0000005kW
Permanent Pilot Flame Requirement N/A
Type of Heat Output / Room Temperature Control Not applicable
Contact Details BFMEurope Ltd.
Gordon Banks Drive
Trentham Lakes North
Stoke-on-Trent
ST4 4TJ
Tel : [phone]

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 Fitting the efficiency / flue restrictor baffle 12
2.7 Fitting the batteries to the fire 12
2.8 Removal & re-fitting of the glass frame 13
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the fuel bed logset 14-18
3.2 Making the gas connection & checking for gas tightness 18
3.3 Removal & re-fitting the trim 19
3.4 Fitting the batteries 20-21
3.5 Lighting the fire manually 21
3.6 Lighting the fire via the remote control handset 22-23
3.7 Checking for clearance of combustion products 24
Section 4 Maintenance
4.1 Removal of the burner assembly 25
4.2 Removal of the control valve 25-26
4.3 Removal of the pilot assembly 26
Section 5 User Instructions
5.1 Installation Information 27
5.2 About the Rocco HE room heater 28
5.3 Spillage monitoring system 28
5.4 Operating the Fire 29-30
5.5 Manual operation of the fire 32-33
5.6 Replacing the batteries 33
5.7 Cleaning instructions 34
5.8 Removal & re-fitting the fuel-bed logset 35-39
5.9 Removal & re-fitting the glass frame 40
5.10 Removal & re-fitting the trim assembly 41
5.11 User replaceable parts 45
Model number FPHL**RN2 manufactured by:-
BFM Europe Ltd. Trentham Lakes, Stoke-on-Trent, Staffordshire, ST4 4T
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APPLIANCE INFORMATION
Main injector : (1 off) Stereomatic Injector Cat 82 – size 380 (NG)
Pilot Type : ERTA PG-83-10
Max. Gross Heat Input : 5.4 kW
Min. Gross Heat Input : 3.0 kW
Gas Rate : 0.512 m3/hr (High)
0.290 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 51.0 kg
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2009 + A1 2013 and the result is 73.9%.
The net 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
BSI. The efficiency value may be used in the UK Government’s Standard
Assessment Procedure (SAP) for energy rating of dwellings.
Fig. 1 Fig. 2
Top View of Combustion Side View of Combustion
Chamber Chamber
3

INSTALLATION REQUIREMENTS
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 CHIMNEY 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.
Minimum diameter of circular flues 125 mm
Minimum effective height of all Class 1 (175mm) flues 3 metres
Minimum effective height of all Class 2 (125mm) flues 4 metres
ENSURE THAT IF INSTALLING THIS PRODUCT INTO A BRIC BUILT
CHIMNEY, THE CHIMNEY HAS BEEN FULLY SWEPT PRIOR TO PROCEEDING
WITH THE INSTALLATION.
Safe clearance of products must always be checked by carrying out a smoke
match test as described in section 3.5
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 figure 3
below.
Fig. 3
5
Combustion Chamber
Opening in Studded Wall or
Existing Chimney Breast
750mm
520mm
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. Secure
combustion chamber via
four off mounting holes
in mounting frame

SECTION 2
INSTALLATION OF FIRE
2.1 UNPAC ING 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 APPLIANCE IF THE
GLASS PANEL IS BRO EN OR NOT SECURELY FIXED TO THE FIREBOX.
Packing Check List
1 off Combustion chamber & glass frame assembly
1 off Trim (packed in front section of outer carton)
1 off Boxed ceramic fuel-bed set (packed inside combustion chamber)
1 off Installation / user Instruction manual
1 off Rubber grommet (to seal inlet aperture used on firebox)
1 off Handset
1 off Loose Items pack – containing :- 1 off efficiency baffle & 2 fixing
screws
4 off No. 12 x 40mm screws
4 off rawlplugs
5 off AA batteries
1 off guarantee card
IMPORTANT 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 CHECKED 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 COMBUSTION CHAMBER OPENING
(INTOSTUDDED WALL) USING A 125MM FLUE LINER.
All combustible parts of the studwork must be set at the distances as shown below
in figure 4 & 5. For installation into such applications a flue box with 125mm flue
pipe adaptor is available to purchase as a cost option extra, please order part
number 1125-130260, from your local Flavel stockist.
7
Minimum 50mm at sides
Minimum 50mm at rear
Combustion Chamber
Dimension “A”
Opening
Width = 750mm
Dim “A”
Dim “B”
Dimension “B”
Opening
Height = 520mm
Dim “C”
Dimension “C”
Opening
Depth = 356mm
Fig. 4
Fig. 5
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
MINIMUM HEIGHT FROM
FLOOR LEVEL TO
BOTTOM OF OPENING IS
150MM

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. See figure 6 below.
Fig. 6
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. This is achieved by a minimum depth of 356mm, the design of the outer
combustion chamber ensures this depth can be met.
Refer to figure 1 on page three for dimensions of the flue outlet.
CHEC ANY LOAD BEARING STRUCTURAL ITEMS ARE NOT
AFFECTED BY THE INSTALLATION OF THE PRODUCT. SEE FIGURE
7 OVERPAGE.
8
Opening Width = 750mm
Opening Height = 520mm
Minimum Depth 356mm
with or without liner
Lintle must
project 150mm
either side of the
opening if
cutting into an
existing chimney
breast

Fig. 7
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 figure 7 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 FIRE TO THE OPENING
2.4.1 The combustion chamber must be secured to the opening via the four
off screw and rawlplugs provided. Figure 8 & 9 below shows the hole
centres in the mounting flanges of the combustion chamber.
Fig. 8
2.4.2 DO NOT SECURE THE COMBUSTION CHAMBER INTO THE
OPENING AT THIS POINT AS ACCESS WILL STILL BE REQUIRED
TO RUN THE GAS SUPPLY PIPEWORK AS DETAILED IN SECTION
2.5
Fig. 9
371mm
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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 figure 10, 11
& 12 below.
Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound. Always insert
the grommet into the entry point used (a sharp blow with a hammer or chisel
will be sufficient to knock out the opening selected in the firebox) and with
the grommet fitted cut with a sharp knife to allow the supply pipework to
pass through into the firebox.
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

2.6 FITTING OF THE EFFICIENCY BAFFLE.
2.6.1 The product is supplied with an efficiency baffle to improve the
efficiency of the product when installed into Class 1 flues, of minimum
diameter 175mm / 7” or brick built 225mm x 225mm chimneys. The
minimum effective height of all flues must be 3 metres or above unless
125mm / 5” then see section 2.6.3
2.6.2 If the product is to be fitted into a Class 1 flue, it may be desirable to fit
the efficiency baffle.
2.6.3 If the product is fitted into a Class 2 flue of diameter 125mm / 5” then
the restrictor baffle must not be fitted. It should also be noted that if
fitting into a 125mm / 5” diameter flue that the minimum effective height
of the flue is 4 metres.
2.6.4 To fit the efficiency baffle (supplied in the loose items pack), use the 2
screws supplied to secure the baffle in position in the roof of the fire as
shown below in figure 13.
Fig. 13
2.7 FITTING OF THE BATTERIES
2.7.1 Please refer to section 3.4
12

2.8 REMOVING / RE-FITTING THE GLASS FRAME ASSEMBLY
2.8.1 The glass frame is held in position by hooking the top flange over the
combustion chamber opening at the top as shown in figure 14 below.
Fig. 14
2.8.2 The assembly is then secured to the bottom of the combustion chamber
by the two hinge clamp brackets as shown below in figure 15. These
are clamped together to form the seal between the glass frame
assembly and the combustion chamber.
Fig. 15
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 figure 15 and lift
clear.
denotes correct
final position of
glass frame.
Combustion
Chamber
13

SECTION 3
INSTALLATION OF FIRE
3.1 FITTING THE FUEL-BED LOGSET
3.1.1 The gravel material should then be first layed around the base of the
combustion chamber as shown below in figure 16, leaving the rear
section as shown to allow the fitting of Log “A”
Fig. 16
3.1.2 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 figure 17.
Fig. 17
Fuel-bed
Log “A” to be
fitted behind
burner flame
strip
14
A

3.1.3 Fit Log “B” into position on left hand side of the fuel-bed base log “A”as
shown below in figure 18, using the groove in Log “A” as a guide for
placement.
Fig. 18
3.1.4 Fit Log “C” into position on left hand side of the fuel-bed base log “A”as
shown below in figure 19, using the groove in Log “A” as a guide for
placement.
Fig. 19
15
B
C

3.1.5 Fit Log “D” into position on left hand side of the fuel-bed base log “A”as
shown below in figure 20, using the groove in Log “A” as a guide for
placement.
Fig. 20
3.1.6 Fit Log “E” into position at centre of the fuel-bed base log “A”as
shown below in figure 21, using the groove in the centre of Log “A” as a
guide for placement.
Fig. 21
16
D
E

3.1.7 Fit Log “F” into position at right hand side of centre of the fuel-bed base
log “A”as shown below in figure 22, using the groove in Log “A” as a
guide for placement.
Fig. 22
3.1.8 Fit Log “G” into position at right hand side of the fuel-bed base log “A”as
shown below in figure 23, using the raised section in the base log as a
guide for position.
Fig. 23
IMPORTANTNOTE
HAVING FITTED THE GRAVEL MATERIAL IN THE BASE OF THE
COMBUSTION CHAMBER, ENSURE THAT NONE OF IT IS ON THE BURNER
FLAME STRIP OR IN THE PILOT ASSEMBLY. IF MATERIAL IS OBSERVED
VISUALLY ON THESE COMPONENTS, REMOVE THE FUEL-BED LOGSET,
REMOVE THE GRAVEL MATERIAL FROM THE BURNER AND OR PILOT AND
RE-FIT THE LOGS AS DETAILED IN SECTION 3.1 ABOVE.
17
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 handling these arti-
cles 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 2.8, then light the appliance as detailed
in section 3.6
3.2 MA ING THE GAS CONNECTION & CHEC ING FOR GAS
TIGHTNESS
3.2.1 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.
3.2.2 The gas connection should be made to the appliance inlet elbow to
using 8mm rigid tubing.
3.2.3 Remove the pressure test point screw from the inlet elbow and fit a
manometer.
3.2.4 Turn on the main gas supply and carry out a gas tightness test.
18

3.3 REMOVAL & RE-FITTING OF THE TRIM ASSEMBLY
3.3.1 The trim is attached to firebox by 4 off magnets as shown below in
figure 24.
Fig. 24
3.3.2 Ensure the trim is securely fitted to the fire.
19
Fit trim to firebox and
secure with 4 off
magnets as shown