Flavel Caress HE Mounting instructions

Caress HE
COAL EFFECT GAS FIRE
Installation, aintenance & User Instructions
Hand these instructions to the user
odel No’s FHEC** N, FHEC**SN & FHEC**RN are only for use on
Natural Gas (G20) at a supply pressure of 20 mbar in G.B. / I.E.
** denotes trim and fret variant

CONTENTS
Section 1 Information and Requirements PAGE
1.0 Appliance Information 3
1.1 Conditions of Installation 4
1.2 Flue and chimney suitability 4
1.3 Fireplace / surround suitability 5
1.4 Shelf position 5
1.5 Chimney inspection 5-6
1.6 Fire place opening / catchment space 6-7
1.7 Fitting to Metal Flue Boxes 7
1.8 Hearths 7
1.9 Spillage Monitoring System 8
Section 2 Installation of Fire
2.1 Unpacking the fire 9
2.2 Installing the fire box 9-18
2.3 Gas tightness and inlet pressure (MC models) 18
2.4 Gas tightness and inlet pressure (SC models) 19
2.5 Gas tightness and inlet pressure (RC models) 19
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 20-24
3.2 Lighting the appliance (Manual Control model) 25
3.3 Lighting the appliance (Slide Control model) 25-26
3.4 Connecting the Battery Pack (Remote Control models) 27
3.5 Fixing the infra-red eye (Remote Control models) 28
3.6 Lighting the appliance (Remote Control model) 29
3.7 Checking for clearance of combustion products 30
3.8 Fitting the Caress trim 31
3.9 Fitting the Caress Contemporary Fender 32
3.10 Fitting the Caress Traditional Fender 33
Section 4 & 5 aintenance
4.1 Removal of the Burner Assembly (Manual Control models) 34
4.2 Removal of the Piezo Igniter (Manual Control models) 35
4.3 Removal of the Control Tap (Manual Control models) 35
4.4 Removal of the Pilot Assembly (Manual Control models) 35-36
4.5 Removal of the Burner Assembly (Slide Control models) 36-37
4.6 Removal of the Battery Ignitor (Slide Control models) 37
4.7 Repacing the Battery (Slide Control models) 37
4.8 Removing the Oxy-Pilot Assembly (Slide Control models) 37-38
4.9 Replacing the Control Cable (Slide Control models) 38-39
5.1 Removal of the Burner Assembly (Remote Control models) 39
5.2 Removing the Remote Gas Valve 39-40
5.3 Removing the Oxy-Pilot Assembly (Remote Control models) 40
5.4 Repacing the Batteries (Remote Control models) 40
Section 6 User Instruction Section
6.1 Conditions of Installation & About Your New Fire 42-43
6.2.1-3 Operating the Fire 44-46
6.2.4 Remote handset malfunction 47
6.2.5 Spillage Monitoring System 48
6.3 Re-Assembling the Ceramics & Fuel-bed 49-53
6.4 / 6.5 Cleaning the Fire & Fuel-bed / Glass Panel 54
6.6 Removal & Re-Fitting the Trim / Fret 55
6.7 User Replaceable Parts 55
2

SECTION 1
INFOR ATION AND REQUIRE ENTS
1.0 APPLIANCE INFOR ATION
Model FHEC**MN (Manual Control)
FHEC**SN (Slide Control)
FHEC**RN (Remote Control)
Gas Type G20
Main injectors (2 off) Size 160
Pilot Type Copreci 21100 / 141 (MC)
Copreci 21100 / 162 (SC & RC)
Max. Gross Heat Input : 5.0 kW
Min. Gross Heat Input : 3.5 kW
Cold Pressure : All models 20.0 +/- 1.0 mbar
Ignition : Push Button Piezo (MC models)
1.5V Battery Generator (SC models)
9V Battery Generator (RC models)
Electrode Spark Gap 4.5mm Nominal
Weights MC Contemporary 24.5kg, Traditional 26.5kg
SC Contemporary 25kg, Traditional 27kg
RC Contemporary 25.5kg, Traditional 27.5 kg
Fire box Dimensions (with trim fitted)
Width : (with standard trim, no spacer) 470mm
Height : (with standard trim, no spacer) 586mm
Depth : (overall-without fender) 250mm
Depth : Flush-fit (from mounting face to rear) 250mm
Depth : Flush-fit (mounting face to rear 200mm
with 50mm spacer fitted)
Gas Connection 8mm Compression (Supplied with fire)
This appliance is manufactured by :-
BFM Europe Ltd, Trentham Lakes, Stoke-on-Trent, ST4 4TJ
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2002 and the result is 80%. 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.
3

INSTALLATION REQUIRE ENTS
1.1 CONDITIONS OF INSTALLATION
It is the law that all gas appliances are installed only by a 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 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 6461 Part 1 Installation of masonary chimneys and flues
7. IS 813 : 1996 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 : 1996 Domestic Gas Installation, which is issued by the
National Standards Authority of Ireland. If installing in Northern Ireland,
please consult local building regulations. In Scotland, please consult the
current edition of the Building standards regulations, issued by the Scottish
Executive. 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 (Without Flue
Restrictor Fitted)
inimum effective height of all flue types 4 metres
When fitting to conventional chimneys or 175mm flues it may be desirable to
fit the flue restrictor baffle (supplied) to reduce the flue flow and increase the
efficiency of the fire. Safe clearance of products must always be checked by
carrying out a smoke match test as described. This product is not suitable
for pre-cast flue’s.
4

1.3 FIREPLACE / SURROUND SUITABILITY
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 150oc. (Class “O”)
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.
1.4 SHELF 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 FLUE / CHI NEY INSPECTION
Before commencing installation, a flue or chimney should be inspected to ensure
that all the following conditions are satisfied.
1. Check that the chimney / flue only serves one fire place and is clear of any
obstruction. Any dampers or register plates must be removed or securely
locked in the open position.
2. Brick / stone built chimneys or any chimney or flue which has been used
for an appliance burning fuel other than gas must be thoroughly swept.
The base of the chimney / flue must also be thoroughly cleared of debris
etc.
3. Any under-floor air supply to the fire place must be completely sealed off.
4. Ensure that the inside of the chimney / flue is in good condition along it’s
length and check that there is no leakage of smoke through the structure
of the chimney during and after the smoke pellet test.
5. Using a smoke pellet, check that there is an up-draught in the
chimney / flue and that the smoke can be seen issuing from the
terminal / chimney pot outside.
There must be no leakage of smoke through the structure of
the chimney during or after the smoke pellet test and it is
important to check inside upstairs rooms adjacent to the chimney /
flue.
5

Check the chimney pot / terminal and general condition of the
brickwork or masonry. If the chimney or flue is in poor condition or if
there is no up-draught do not proceed with the installation. If there is a
history of down-draught conditions with the chimney / flue, a tested and
certificated flue terminal or cowl suitable for the relevant flue type should
be considered.
6. A spillage test must always be carried out during commissioning of
the appliance.
1.6 FIRE PLACE OPENING AND CHI NEY CATCH ENT SPACE
The front opening of the fire place must be between 400 and 450 mm wide, and
between 550 and 570mm high. If the opening exceeds these dimensions then a
surround must be constructed from suitable non-combustible material to produce a
correct size opening. Any surround must be suitably sealed to the fire place to
prevent leakage. See below in fig.1
When installing into a brick built chimney, you must ensure that there is sufficient
depth to accomodate any debris which may fall from the chimney. This depth
must be sufficient to accomodate 12 litres of volumetric space.
Fire Opening
400mm Minimum
450mm Maximum
580mm
Minimum
470mm Minimum
Fig. 1
550mm Minimum
570mm Maximum
Minimum Flat
Sealing Area
6

Table A - Installat on Depth Requ rements for a Flavel Caress HE be ng
nstalled nto a br ck bu lt ch mney, requ r ng 12.0 l tres of debr s collect on
volume (f g. 2)
When installing this product into a brick built chimney, there must be a minimum
depth available of 300mm available for the collection of debris behind the firebox
when installed.
See fig. 2a below for explanatory diagram.
Fig. 2a
1.7 FITTING TO PRE-FABRICATED TWIN WALL ETAL FLUE BOXES
The appliance may be fitted to twin wall metal flue boxes conforming to the
constructional requirements of BS 715, (for example the Selkirk LFE 175 box).
The box must have a minimum flue diameter of 125mm internal and minimum
internal dimensions of 275mm deep by 580mm high by 400mm wide. The top face
of the box must be insulated with a minimum thickness of 50mm of
non-combustible mineral wool insulation or similar material. The flue box must
stand on a non-combustible base of minimum thickness 12mm if the flue box
being utilised is of single skin construction.
1.8 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.
7
Firebox
Depth Required
300mm
Minimum
VOID FOR FLUE DEBRIS COLLECTION

1.9 SPILLAGE ONITORING SYSTE
This appliance is fitted with an atmosphere sensing spillage monitoring system in
the form of an oxygen sensing pilot. This is designed to shut the fire off in the
event of a partial or complete blockage of the flue causing a build up of
combustion products in the room in which the fire is operated. The following are
important warnings relating to this spillage monitoring system :-
1) The spillage monitoring system must not be adjusted by the installer.
2) The spillage monitoring system must not be put out of operation.
3) When the spillage monitoring system is exchanged only a complete original
manufacturers part may be fitted. It is not possible to replace individual parts on
the pilot system on this appliance, only a complete pilot assembly (including the
thermocouple) may be fitted.
8

SECTION 2
INSTALLATION OF FIRE
2.1 UNPACKING THE FIRE
Carefully lift the fire out of the carton. Remove the loose item packaging carefully
from the front of the appliance. Check the contents as listed :-
Packing Check List
1off Fire box / burner assembly
1off Boxed ceramic base, front ceramic rail and 19 coals (4 off “FR”coals 9 off “L” large & 6 off
“S” small coals) - packed inside combustion chamber.
1off Loose items bag including remote handset and 6AA / 1 off 9Vbattery on RC models, flue
restrictor baffle, mounting brackets for cast iron trim / contemporary fret mounting brackets.
1off each Installation & Maintenance / User Instruction Book
1 off each Contemporary or Tradutional Fret & Cast Iron Trim
2.2 INSTALLING THE FIRE BOX
Establish which type of flue you are intending to install the fire in to :-
225 x 225mm (9 inch x 9 inch) brick built chimneys 175mm (7 inch) diameter lined
brick or stone flue, insulated pre-fabricated metal flue box to BS 715 / BS EN
1856-2. When installing into 125mm (5 inch) diameter lined brick or stone flue, or
insulated pre-fabricated metal flue box and liner to BS 715 / BS EN 1856-2 the
restrictor baffle must not be fitted.
The flue restrictor baffle (supplied in the loose items) should only be used in
225 x 225mm (9 inch x 9 inch) brick built chimneys where the flue pull is
excessive. It must not be fitted if installing the product into a metal flue box
or 125mm diameter lined flue. See fig 2b / 2c below for details on fitting /
removing the restrictor baffle onto the spigot on the rear of the firebox.
A spillage test must always be carried out to check satisfactory clearance of
flue products, regardless of the type of flue the appliance is being fitted to.
9
Fig 2b -Flue Restrictor
Baffle Not Fitted
Fig 2c - Flue Restrictor
Baffle Fitted via 3 screws
as s own
3 screws

For all models proceed as follows :-
a) Remove the top glass retaining cover from the product. It is secured via
the four screws as indicated, 2 off L/H/S and 1 off R/H/S. See fig. 3
below.
Fig. 3
b) Remove the left and right hand side glass securing brackets from the
product. They are secured via 2 off screws each side. See fig. 4
below.
Fig. 4
10
2 off securing
screws L/H/S
1 off securing
screw R/H/S
2 off securing
screws L/H/S
2 off securing
screw R/H/S

c) Lift the glass panel forwards and clear from the firebox, taking care not
to damage the glass panel, remove the ceramics and store in a safe
place. See fig. 5 below
Fig. 5
d) Remove the burner heat shield, which is retained by 2 off screws as
shown below in fig. 6
Fig. 6
11
Burner Heat
Shield Retaing
Screws

For all anual Control models proceed as follows :-
e) Remove the two off screws from the left and right hand burner
mounting brackets, plus the two screws from the base of the control
panel as shown below in Fig. 7, this will allow removal of the complete
burner unit from the firebox.
Fig. 7
For all Remote Control models proceed as follows :-
f) Remove the two off screws from the left and right hand burner
mounting brackets, plus the two screws from the base of the control
panel as shown below in Fig. 8, this will allow removal of the
complete burner unit from the firebox.
Fig. 8
12
4 off burner
retaining screws
4 off burner
retaining screws

For all Slide Control models proceed as follows :-
f) Remove the burner. To allow burner removal, the control lever
operating cable must be removed. The control lever operating cable
can be seen running across the base of the fire, below the burner. To
release the cable, unscrew the cable securing screw located in the
centre of the aluminium operating arm and pull the cable out from its
fixing hole. Release the other end of the cable by pushing the cable
forwards to the right, i.e. into the operating arm so as to release the
tension. Pull the cable nipple out of the retaining hole and remove the
cable through the slot in the operating arm. See fig. 9 below.
Fig. 9
g) Remove the two off screws from the left and right hand burner
mounting brackets, plus the two screws from the base of the control
panel as shown below in Fig. 10, this will allow removal of the complete
burner unit from the firebox.
Fig. 10
13
4 off burner
retaining screws

Continue for all models as follows :-
Whilst the fire box is still in position, decide which side the gas supply is to enter
the fire from. 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 below the
fuelbed support panel and connect to the isolating / inlet elbow. The gas
connection to the appliance should be made to the isolating / inlet elbow using
8mm rigid tubing. There must be no soldered joints within the firebox. See fig. 11
& 12 below for suggested concealed pipe layouts.
Fig. 11
Fig. 12
Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound.
Carefully withdraw the fire box from the opening to enable the gas supply and fire
fixing to be completed.
14
Firebox
Fireplace
Builders
Opening
Gas Supply
Firebox
Approx.
40mm Fireplace
Gas Supply
Approx.
40mm
Builders
Opening

I PORTANT : Sealing of the Gas Unused Gas Pipe Inlet Apertures
In line with current regulations, it is imperative that the gas supply inlet aper-
tures that are not utilised during the installation are sealed with the foil tape
as supplied. Failure to seal these inlet apertures could lead to flame
reversal, which in turn will damage the burner and control systems of the product.
Fig. 13 below shows a correctly sealed installation.
Fig. 13
PLEASE NOTE :-
BF EUROPE LTD.. WILL NOT BE LIABLE FOR
GUARANTEE CLAI S THAT ARE AS A DIRECT
RESULT OF THE UNUSED GAS INLET APERTURES
NOT BEING CORRECTLY SEALED.
Seal off unused gas inlet
apertures as shown
15

The preferred method of fixing which is suitable for almost all situations is
the cable fixing method which is described in the following section in detail.
To fit using the preferred cable method proceed as follows-
h) Mark out and drill 4 off No 14 (6mm) holes in the back face of the fire
opening in the positions shown below in fig. 14.
Fig. 14
Fit the wallplugs provided and screw the fixing eyes securely into the rear of the
fire opening. If the clearance at the rear of the fire is at the minimum specified for
a precast flue application, it may be necessary to bend over the lower fixing eyes
after screwing them fully in to the rear of a pre-cast starter block.
i) Uncoil the two fire fixing cables and thread one end of each of the
cables through one of the two holes on each side of the flue outlet
shroud.
j) Position the fire carefully on the (protected) surface of the hearth and
reach into the fire opening. Thread each of the cables vertically
downwards through the pair of fixing eyes on the same side of the fire.
Thread the free end of the cables through the corresponding circular
hole on each side of the lower rear of the fire. Carefully slide the fire
box back into the fire opening and pull both cables tight.
k) Thread a tensioning screw over each 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).
l) 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. See fig. 15 overpage.
16
20mm
500mm Fireplace Opening
100mm
250mm

Fig. 15
m) Evenly tighten the tensioning nuts to tension both cables and pull the
fire snugly against the wall. Do not overtighten, it is only necessary to
pull the seal up against the sealing face of the wall, it does not need to
be compressed. Check that there are no gaps behind the seal.
n) With the fire securely in place, if a concealed gas connection has been
made through either of the access holes in the sides of the fire, the
holes should be closed around the pipe to prevent leakage of air
through the gap around the pipe.
o) Refit the burner. Fit the four retaining screws on manual and slide
control models or two screws on Remote control models and check that
the burner is correctly locked into position. On slide control models refit
the control cable To do this, firstly locate the nipple on one end of the
cable into recess in operating arm and then secure the front part of the
operating arm back onto the rear of the operating arm with the retained
screw.
This should not be overtightened. Move the control lever fully
downwards and check that the left hand micro-switch operates the
igniter and that the control valve spindle is fully depressed. Move the
control lever upwards to the “off” position and check that the right hand
(cut-off) micro-switch operates. Check that the control lever operates
smoothly and safely.
NOTE : The cable is factory set, and therefore should need no adjustment
p) Refit the front burner heat shield to the sides of the fire box (2 Screws)
and secure the trim to the fire.
17

q) 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.
The other firebox fixing method is as follows :-
In installations where the cable method is not suitable (e.g. loose masonary in rear
of fire opening) the firebox can be secured to the fire surround using four screws
and wall plugs provided. Below (fig.16) is a diagram to indicate the hole centre
positions available on the firebox to facilitate the screw fixing to the fireplace /
surround.
Fig. 16
2.3 GAS TIGHTNESS AND INLET PRESSURE ( ANUAL CONTROL
ODELS)
a) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
b) Turn on the main gas supply and carry out a gas tightness test.
c) 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.
d) Check that the gas pressure for Natural Gas (G20) models is 20.0 mbar
(+/- 1.0mbar) 8.0 in w.g.(+/- 0.4 in w.g.)
e) 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.
18
532mm
260mm
55mm
Firebox
Mounting
Flange
425mm

2.4 GAS TIGHTNESS AND INLET PRESSURE (SLIDE CONTROL
ODELS).
a) Remove the pressure test point screw from the pressure test point and
fit a manometer.
b) Turn on the main gas supply and carry out a gas tightness test.
c) Depress the control lever to the position marked pilot. Hold down the
control lever for a few seconds to purge the pipe work. The burner
should light, continue to hold the control lever for a few seconds to latch
the valve then lift to the full-on position.
d) Check that the gas pressure for Natural Gas (G20) models is 20.0 mbar
(+/- 1.0mbar) 8.0 in w.g.(+/- 0.4 in w.g.)
e) 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.
2.5 GAS TIGHTNESS AND INLET PRESSURE (RE OTE CONTROL
ODELS).
a) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
b) Turn on the main gas supply and carry out a gas tightness test.
c) Depress both the round buttons on the handset. The fire will then
commence its ignition sequence and will light to high. See page 29
for full details of the operating method for the fire.
d) Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.)
e) 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.
19

SECTION 3
ASSE BLING FUEL BED AND CO ISSIONING
3.1 ASSE BLING THE CERA ICS AND FUEL BED
a) Place the ribbed ceramic fuelbed base on top of the fuelbed support
and pull fully forwards to the burner. ake sure that the fuelbed
base is located centrally in the fire box.Ensure that the fuelbed
base fit fully down onto the fuel bed support and is not
lodged on the burner. Ensure the air ports as indicated by the
arrows are not blocked by the fuel-bed matrix. See fig. 17& 18
below.
Fig. 17
Fig. 18
20
NOTE : T e position of t e fuel-bed components are critical to t e
performance of t e product. T erefore please ensure t at t e fuel-bed
components are positioned as described in t e following section prior to
requesting a service call due to soot build up, poor flame pattern etc.
C eck air ports in fuel-bed base panel are not obstructed.
If t ese air ports are not in line wit t e oles in t e fuel-
bed base matrix do not proceed wit t e installation
Air ports in Fuelbed base mounting panel