Flavel Calibre FBFC**MN2 Mounting instructions

Calibre
COA EFFECT BA ANCED F UE GAS FIRE
Installation, Maintenance & User Instructions
Hand these instructions to the user
Model No. FBFC**MN2, FBFC**RN2 & FBFC**EN2 are for use on Natural Gas
(G20) at a supply pressure of 20 mbar in G.B. / I.E.
Model No. FBFC**MP2 is for use on Propane Gas (G31) at a supply pressure
of 37 mbar in G.B. / I.E.
** denotes trim / fret or fascia 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
Section 2 Installation of Fire
2.1 Unpacking the fire 6
2.2 Fireplace opening 7-8
2.3 Preparation of the wall 8-9
2.4 Preparation of the flue hole 9
2.5 Installation of the gas supply 10
2.6 Preparation of the flue duct 11
2.7 Securing the firebox to the opening 12-13
2.8 Making the gas connection 13
2.9 Fitting the terminal guard 14
2.10 Removal & refitting of the glass frame 15
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the fuel bed 16-18
3.2 Fitting the trim 18
3.3 Fitting the fret 18
3.4 ighting the appliance (MC variants) 19
3.5 Fixing the infrared sensor in position (RC variants) 20
3.6 Connecting the battery pack (RC variants) 21
3.7 ighting the appliance (RC variants) 22
3.8 ighting the appliance (EFC variants) 23
Section 4 Maintenance
4.1 Removal of the burner assembly (all variants) 24
4.2 Removal of the piezo Igniter (MC variants) 24
4.3 Removal of the control valve (MC variants) 25
4.4 Removal of the pilot assembly (all variants) 25
4.5 Removal of the control board (RC & EFC variants) 26
4.6 Removal of the control valve (RC & EFC variants) 26
4.7 Removal of the IR sensor (RC variants) 26
4.8 Removal of the battery holder / lead (RC & EFC variants) 26
4.9 Removal of the EFC trim switch 27
4.10 Parts shortlist 27
Section 5 User Instructions
5.1 Installation Information / about your fire 28-29
5.2 Operating your fire (MC variants) 30
5.3 Operating your fire (RC variants) 31
5.4 Operating your fire (EFC variants) 32
5.5 Turning off the RC / EFC model if the handset is lost or broken 33
5.6 Changing the batteries (RC / EFC variants) 33
5.7 Removal / replacing the glass frame 34
5.8 Removal / replacing the fuel-bed 35-37
5.9 User replaceable parts 38
BFM Europe td, Trentham akes, Stoke-on-Trent, Staffordshire, ST4 4TJ
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APP IANCE INFORMATION
Natural Gas PG
Main injector : (1 off) 1.65mm 1.20mm
Pilot Type - S.I.T.140 Series Size 27 Size 19
Max. Gross Heat Input : 4.6kW 4.8kW
Min. Gross Heat Input : 3.2kW 3.4kW
Gas Rate : 0.427 m3/hr 0.180 m3/hr
Cold Pressure : 20.0+/-1.0 mbar 37.0+/-1.0 mbar
Ignition : Push-button Piezo (MC models only)
Ignition : Electronic (RC & EFC models only)
Electrode Spark Gap : 4.0mm
Weight (without fender) : 25.0 kg inclusive of flue pipe and terminal
Fig 1
3
185mm
285mm Min, 625mm Max with standard flue
duct on MC / C models. 248mm Min,
588mm Max with standard flue duct on EFC
models. A cost option extended flue duct (part
no. CV-MA LT) can be purchased to increase
this dimension on NG MC / C models to
1010mm or 973mm on NG EFC models)
120mm
580mm
550mm
150mm

INSTA ATION REQUIREMENTS
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS EN 613 : 2001 and the result is 85%. 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 BSI Testing
Services.
The efficiency value may be used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings.
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 ocal 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
This product is designed to fit fireplaces with a minimum 1” / 25mm rebate. 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 proprietary fire place surrounds with a
temperature rating of at least 150 degrees celcius (Class “O”).
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 con-
sideration 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 200mm 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 must only be installed on to a concrete or non-combustible hearth.
The hearth material must be a minimum thickness of 12mm with the top surface at
least 50mm above the floor. The hearth must be fitted symmetrically about the fire
opening and have a minimum width of 760mm and a minimum projection of
300mm forwards from the fire opening.
SECTION 2
INSTA ATION OF FIRE
2.1 UNPACKING THE FIRE
Carefully lift the fire out of the carton. Remove the loose item packaging carefully
from the the pack. Check the contents as listed :-
IMPORTANT : THE CARDBOARD FITMENT THAT IS AT THE TOP OF THE
CONVECTION APERTURE SHOU D NOT BE REMOVED
UNTI THE APP IANCE IS FU Y INSTA ED AND READY
TO BE IT.
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 ist
1 off Fire box & foam seal / burner assembly
1 off Boxed ceramic 5 piece fuel bed set
1 off Flue terminal / pipe unit
1 off Flue terminal guard
1 off oose Items pack including cable fixing kit
1 off Installation / user manual (combined)
6 off AA batteries (RC / EFC models only)
1 off PP3 battery (RC models only)
1 off Rubber grommet (to seal gas aperture used)
1 off Trim
1 off Fret & ashpan cover
6

2.2 FIRE P ACE OPENING
2.2.1 The front opening of the fire place must be between 410 and 420mm
wide, and between 555 and 570mm high. If the opening exceeds these
dimensions then a surround must be constructed from suitable non-
combustible material to produce a suitable sized opening. Any surround
must be suitably sealed to the fire place to prevent leakage.
See fig. 3 below
Fig. 3
2.2.2 The minimum / maximum sized distances between the firebox mounting
flange and outside wall are shown below in Fig. 4
Fig. 4
7
590mm minimum
490mm minimum
Fire Opening
410mm minimum
420mm maximum
555mm
minimum,
570mm
maximum
Minimum Flat
Sealing Area
Minimum Installation Depth
285mm MC / C models
Minimum Installation Depth
248mm EFC models
Maximum Installation Depth 625mm
with standard flue duct MC / C models
Maximum Installation Depth 588mm
with standard flue duct EFC models
Maximum Installation Depth
1010mm with extended flue duct
on MC / C models
973mm on EFC models (cost
option extra) - suitable for NG
models only on all control options

2.2.3 NOTE : WHEN MEASURING ENGTH BETWEEN FIREBOX AND
THE OUTER WA TAKE INTO ACCOUNT THE DISTANCE
BETWEEN THE BACK OF THE FIREBOX AND THE INNER WA AS
THIS WI VARY BETWEEN INSTA ATIONS, DEPENDENT UPON
THE FIRE SURROUND REBATE OR CAVITY DEPTH. (DIMENSION
“X” BE OW - FIG. 5).
Fig. 5
2.2.4 The appliance must be fitted into a fireplace or false chimney
constructed of non-combustible materials, minimum width 410mm,
minimum height 555mm and minimum surround or false chimney breast
rebate 75mm.
2.3 PREPARATION OF THE WA
2.3.1 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 floor to the centre of the flue is
shown on fig. 6 overpage.
760mm
405mm 185mm
X
Outer Wall
Inner Wall
485mm Including
Firebox Flanges
8
300mm
Cavity
Flue Terminal

Fig. 6
2.4 PREPARATION OF THE F UE HO E
2.4.1 Mark the position of the centre of the flue on the inner wall.
2.4.2 Cut hole for outer flue pipe. There are two possible methods to achieve
this, either core drill or via hammer and chisel.
2.4.3 To core drill, proceed as follows :-
Drill a pilot hole through the wall, in position as specified in figure 6.
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 6.
Mark the position of the hole around this point.
Chisel out the area as marked on the wall.
2.4.4 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.
150mm diameter
423mm
9

2.5 INSTA ATION OF THE GAS SUPP Y
2.5.1 Before installing the firebox, decide from which side or if a rear
connection to the gas supply is required. Plan the pipe run to enter the
firebox from the left, right or rear and connect to the inlet elbow. See
below :-
2.5.2 If concealed pipe work is required plan the pipe run to enter the fire box
through one of the openings in the sides or rear of the fire box and
connect to the inlet elbow. See Fig. 7 & 8 below for a suggested
concealed pipe layout.
Fig. 7
Fig. 8
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.
10
Firebox
Fireplace
Gas Supply
Firebox
Approx.
40mm Fireplace
Gas Supply
Approx.
40mm

2.6 PREPARATION OF THE F UE DUCT
2.6.1 Place the firebox into the fire opening with fire surround correctly
secured in the final position. From the outside of the house measure
from the face of the outside wall to the rear panel of the firebox through
the flue hole. Cut the flue duct to this size, using the polythene support
ring to support the flue whilst being cut. Remove the polystyrene
support ring from the flue duct and remove burrs from the pipe.
IMPORTANT : ENSURE THE PIPES ARE CUT SQUARE Y.
2.6.2 The joint between the firebox and the flue duct as shown below in Fig. 9
must be secured with screws and sealed with the foil tape as supplied.
In order to do this, the wall plate must removed from the flue pipe /
termination.
Fig. 9
2.6.3 Due to the varying lengths of flue that will be required via differing
installations it will be necessary to drill the flue pipe using the 3 off holes
in the mounting flange on the rear of the combustion chamber as a
guide for positioning. When the holes have been drilled and the screws
fitted, wrap the joint with the foil tape supplied.
2.6.4 Re-fit the wall plate ensuring the outer set of holes as indicated above
in Fig. 9 are used. Use a high temperature sealant to secure the wall
plate to the outside wall of the property before securing with the screws
and rawlplugs supplied to ensure a mechanical fix.
11
Lug as shown
should be fitted
uppermost
Wall Plate
Flue
Termination / Pipe
Use the outer set of holes to
secure the wall plate to the
flue pipe / termination

2.7 SECURING OF FIREBOX TO THE OPENING
2.7.1 There is a choice of methods of fixing the firebox that are provided to
enable the installer to deal with any type of installation. The preferred
method of fixing the appliance is the cable fixing method, which is
described in detail in the following section.
2.7.2 If the standard firebox fixing flange is to be used, the firebox may be
secured using the cable method, but in installations where the cable
method is not suitable, e.g.insufficient space behind the firebox, or
loose masonry, the firebox can be fitted directly to either the front of the
fireplace via the flange with the four off screws provided. The firebox will
require sealing to the fireplace, regardless of the method used.
2.7.3 To secure the fire using the preferred cable method, proceed as follows
below :-
2.7.4 Mark out and drill 4 off No 14 6mm holes in the rear face of the fire
opening in the positions as shown in Fig. 10 below.
Fig. 10
2.7.5 Fit the wall plugs provided and screw the fixing eyes securely into the
rear of the fire opening.
2.7.6 Uncoil the two fire fixing cables and thread one end of the each of the
cables through the rear of the fire box, and through each fixing eye at
the top. Thread both cables through the fixing eye’s at the bottom, then
the holes at the bottom of the firebox
2.7.7 Thread the cables through the rear of the firebox, insert the flue pipe /
terminal through the hole in the rear of the opening and offer the firebox
up to the fireplace.
12
360mm
500mm
50mm

2.7.8 To improve access to tension the screws it may be advantageous to
remove the control panel from the fire. To do this, remove the 4 off
retaining screws and on MC models, remove the control valve retaining
nut.
2.7.9 Thread a tensioning screw over both of the cables and ensure that the
tensioning nut is screwed fully up against the hexagon shoulder of the
tensioning screw (this provides maximum travel for the tensioning nut).
2.7.10 Fit a screwed nipple on to each of the cables and pull hand tight up
against the tensioning screw, then secure each nipple with a flat bladed
screwdriver.
2.7.11 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.
2.8 MAKING THE GAS CONNECTION / PRESSURE TESTING
2.8.1 The gas connection should be made to the appliance inlet elbow to
using 8mm rigid tubing.
2.8.2 Remove the pressure test point screw from the inlet elbow and fit a
manometer.
2.8.3 Turn on the main gas supply and carry out a gas tightness test.
2.8.4 Depress the control knob and turn anti-clockwise to the position marked
pilot. Hold in the control knob for a few seconds to purge the pipe work
then press the igniter button. The burner should light, continue to hold
the control knob for a few seconds then turn to the full-on position. If
lighting an RC or EFC variant , please consult section 3.5 to 3.8.
2.8.5 Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.) for NG models and 37.0 mbar (+/- 1.0mbar) 14.8 in
w.g.(+/- 0.4 in w.g.) for PG models
2.8.6 Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.
13

2.9 FITTING THE TERMINA GUARD
2.9.1 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.
2.9.2 Remove the terminal guard and drill the 4 off 6 mm holes.
2.9.3 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.
NOTE : In England & Wales, 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.
14

2.10 REMOVING & REFITTING OF THE G ASS FRAME.
2.10.1 Remove the 2 screws which hold the convection slot cover to the
firebox, as shown below in Fig 11
2.10.2 Remove the burner heat shield by unscrewing the 2 off retaining screws
as shown below in Fig. 11
2.10.3 Remove the 4 off M5 retaining nuts as shown below in Fig. 11
2.10.4 Remove the 3 off top retaining screws as shown below in Fig. 11
2.10.5 Remove the 2 off bottom retaining screws as shown below in Fig. 11
2.10.6 Re-assemble in reverse order.
NOTE : Always ensure that a consistent seal between the combustion
chamber and the glass frame is achieved.
Fig. 11
15
Burner heat
shield, secured by
2 screws
Glass frame assembly,
secured by 5 off
screws and 4 off M5
retaining nuts
Convection slot
cover, secured by 2
screws

SECTION 3
ASSEMB ING FUE BED AND COMMISSIONING
3.1 FITTING THE FUE BED
3.1.1 Place the ceramic fibre support behind the burner as shown below in
Fig. 12
Fig. 12
3.1.2 Place the front right coal moulding onto the front coal support as shown
below in Fig. 13
Fig. 13
16
ight Front Coal Moulding
Front Coal Support

3.1.3 Place the front left coal moulding onto the front coal support as shown
below in Fig. 14
Fig. 14
3.1.4 Place the upper right coal moulding as shown below in Fig. 15. This
moulding tucks under the front right coal moulding and is supported by
the ceramic fibre support.
Fig. 15
17
Left Front Coal Moulding
Upper ight Coal Moulding

3.1.5 Place the upper left coal moulding as shown below in Fig. 16. This
moulding tucks under the front left coal moulding and is supported by
the ceramic fibre support.
Fig. 16
3.1.5 Refit the glass frame as detailed in section 2.10, then light the
appliance as detailed in section 3.2 / 3.3
To ensure that the release of fibres from these R.C.F (Refractory Ceramic
Fibre) articles is kept to a minimum, during installation and servicing we
recommend that you use a HEPA filtered vacuum to remove any dust
accumulated in and around the appliance before and after working on the
appliance. When replacing these articles we recommend that the replaced
items are not broken up, but are sealed within heavy duty polythene bags,
clearly labelled as “RCF waste”. RCF waste is classed as a “stable”, non
reactive hazardous waste and may be disposed of at a landfill licensed to
accept such waste Protective clothing is not required when handling these
articles, but we 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.
3.2 FITTING THE TRIM (A MODE S)
3.2.1 The trim is held in position on the fixing flange by magnets.
3.3 FITTING THE FENDER (A MODE S)
3.3.1 The fender is placed up to the front of the ceramic front rail on
all models. Position the ashpan under the fender and centralise.
18
Upper Left Coal Moulding

3.4 IGHTING THE APP IANCE - MANUA CONTRO VARIANTS
IMPORTANT NOTE : IF THE BURNER IS EXTINGUISHED FOR ANY
REASON YOU MUST ENSURE THAT YOU WAIT A FU FIVE
MINUTES BEFORE ATTEMPTING TO RE- IGHT THE FIRE.
WHEN TURNING THE FIRE “OFF” P EASE ENSURE THAT THE
CONTRO VA VE IS TURNED TO THE “OFF” POSITION AND THE
PI OT F AME IS EXTINGUISHED. DO NOT EAVE THE PI OT
F AME ON Y IT.
3.4.1 Turn on the gas restrictor at the inlet fitting.
3.4.2 Depress the control knob and turn anti-clockwise to the position marked
pilot. Hold in the control knob for a few seconds to purge the pipe work.
3.4.3 Continue to hold-in the control knob and press the igniter button. If the
burner does not light, continue to press the igniter button until ignition
occurs. Continue to hold the control knob for 5-10 seconds to allow
thermocouple to heat up, if the pilot goes out when the control knob is
released, repeat the lighting sequence.
3.4.4 Turn the control knob in the anti-clockwise direction to the high position
and the main burner will light.
3.4.5 Turn the control knob clockwise to the low position and the gas input
will be reduced to the minimum setting.
3.4.6 Slightly depress the control knob and turn to the pilot position, the main
burner will go out but the pilot will remain lit.
3.4.7 Slightly depress the control knob and turn to the off position, the pilot
will now be extinguished.
3.4.8 After ensuring that the fire is safe to use it should be left on high
position to fully warm up. During this time a slight odour may be
noticed, this is due to the “newness” of the fire and will soon disappear.
Finally, hand the Installation and Maintenance Instructions and the Users
Instructions over to the customer and explain the operation of the fire.
NOTE : THIS APP IANCE IS DESIGNED TO WORK SAFE Y AND
EFFECTIVE Y DURING ADVERSE WEATHER CONDITIONS.
HOWEVER, DURING SUCH TIMES F AME DISTURBANCE
MAY BE NOTICED. THIS IS NORMA AND DOES NOT
EFFECT OR IMPAIR THE SAFETY OF THE APP IANCE.
19

3.5 FIXING THE INFRARED SENSOR IN POSITION - REMOTE
CONTRO MODE S ON Y
3.5.1 Due to the different fascia’s that can be supplied with these fires, the
infrared sensor is supplied from the factory attached to a self adhesive
pad. This pad can therefore be attached to the hearth in a position to
suit the form of the fret assembly that is chosen with the product.
Fig. 17 below shows the self adhesive pad and infrared eye attached
to the flying lead, as supplied from the factory.
Fig. 17
3.5.2 Remove the backing paper from the self adhesive pad and position the
infrared eye in the air channels in the ashpan cover, so that the infrared
eye is flush with the front edge of the ashpan cover, as shown below in
Fig. 18. Check the operation of the fire / handset, as detailed in Section
3.7 and adjust the position of the infrared eye if necessary.
Fig. 18
20
Infrared Eye
Flying Lead
Infrared Eye Sensor
Self Adhesive Pad
Correct final position
of the Infrared Eye
Sensor