Flavel Castelle Mounting instructions

Castelle
INSET FUEL EFFECT GAS FIRE
Installation, aintenance & User Instructions
Hand these instructions to the user following installation
odel No’s FPCL**RN is only for use on Natural Gas (G20) at a
supply pressure of 20 mbar in G.B. / I.E.
** denotes colour 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 4
1.4 Shelf position 5
1.5 Chimney inspection 5
1.6 Fire place opening / catchment space 6
1.7 Fitting to chair bricks 8
1.8 Precast flues 8
1.9 Metal flue boxes 8
1.10 Wall / hearth mounting 9
1.11 Spillage monitoring system 10
Section 2 Installation of Fire
2.1 Unpacking the fire 11
2.2 Installing the firebox 11
2.3 Preparation of firebox opening 12-17
2.4 Gas tightness and burner pressure 17
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 18-22
3.2 Fitting the fascia 23
3.3 Lighting the appliance 24-25
3.4 Checking for clearance of combustion 33
products
3.5 Removal & re-fitting the draught diverter cover 27
3.6 Removal & re-fitting the flue restrictor baffle 28
Section 4 aintenance
4.1 Removal of the burner assembly 29
4.2 Removal of the gas valve 29-30
4.3 Removal of the pilot assembly 30
4.4 Removal of the batteries in the receiver 30
Parts shortist 31
Section 5 User Instructions
5.1 Conditions of Installation / about your new fire 32-33
5.2 Operating the fire 34-35
5.3 Spillage monitoring system 35
5.4 Re-assembling the fuel-bed 36-40
5.5 Removal & re-fitting the glass fascia 41
5.6 Removal & re-fitting the draught diverter cover 42
5.7 Cleaning the fuel-bed / glass fascia assembly 43
User replaceable parts 44
This appliance is manufactured by :-
BFM Europe Ltd,
Trentham Lakes, Stoke-on-Trent, ST4 4TJ
2

SECTION 1
INFOR ATION AND REQUIRE ENTS
1.0 APPLIANCE INFOR ATION
Model FPCL**RN
Gas Type G20
Main injector (1 off) Size 1.65mm
Pilot Type S.I.T. Oxystop YA OP 9061
Max. Gross Heat Input : 5.0kW
Min. Gross Heat Input : 2.8kW
Cold Pressure : 20.0 +/-1.0 mbar
Ignition : 6V Battery Generator
Electrode Spark Gap 4.0mm
Weight 29.5kg
Firebox dimensions
Width : (with fascia fitted) 750mm
Height : (with fascia fitted) 600mm
Depth : (overall-with fascia) 223mm
Depth : (from mounting face) 75mm
Gas Connection 8mm Compression (Supplied with fire)
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2009 and the result is 71.2%.
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.
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 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 : 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. 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 3 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.
4

1.3 FIREPLACE / SURROUND SUITABILITY
The fire must not be installed directly onto carpet or other combustible floor
materials. See page 9 for further details regarding hearth panels.
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.
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 over-
hang 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 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. With pre-cast flues
it is especially important to check the inside of the flue for extruded
cement / sealant protruding from the joints between the flue
blocks. If present, these should be removed by rodding the flue
before proceeding with the installation.
5. Using a smoke pellet, check that there is an up-draught in the chim
ney / flue and that the smoke can be seen issuing from the terminal /
chimney pot outside.
5

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. 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 350mm and 400mm wide,
and between 490 and 500mm 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 figure 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
350mm Minimum
400mm Maximum
520mm
Minimum
420mm Minimum
Fig. 1
490mm Minimum
500mm Maximum
NOTE : Mini u
25 clearance
for fascia also
required below
botto edge of
opening
Minimum Flat
Sealing Area
6

Table A - Installation Depth Requi ements fo a Flavel Castelle being
installed into a b ick built chimney, equi ing 12.0 lit es of deb is collection
volume (figu e 2).
The chimney requires a minimum of 50mm clearance when measured from the
mouting face of the fire behind the firebox to accomodate 12.0 litres of debris
collection.
See figure 2 below for explanatory diagram.
Fig. 2
1.7 FITTING TO FIREPLACES WITH EXISTING CHAIRBRICKS AND
CONVENTIONAL BRICKBUILT CHI NEYS
This appliance is suitable for use in fireplaces fitted with an existing chairbrick
without the need for removal of the chairbrick, providing the minimum depth of the
fireplace from mounting face to chairbrick exceeds 125mm. The fireplace must be
checked to ensure that no part of the chairbrick is within 50mm of the flue outlet of
the fire when installed.
7
Opening Width ( e.g. 400mm)
Depth Required
(e.g. 125mm)

1.8 FITTING TO PRE-CAST FLUE INSTALLATIONS
To install the fire box in to pre-cast flue starter blocks, there must be at least
100mm from the mounting face of the fire to the rear of the pre-cast flue
starter block to allow sufficient space for debris collection. It is important to
consider this depth if choosing a fire surround as the thickness of the fire surround
must be sufficient to give a total depth of at least 100mm to the rear of the
starter block, otherwise there will be insufficient depth. To increase this depth the
fire surround may be packed away from the wall using suitable non-combustible
board, providing the installation is correctly sealed. If in doubt about the suitability
of the fire contact BFM Europe Ltd. for advice before proceeding.
It is important to ensure that the pre-cast flue is in good condition and is free from
extruded mortar or sealant from between the flue blocks.
This appliance has been tested for use in a pre-cast flue block complying
with BS EN 1858. In accordance with BS EN 1858, pre-cast flues built with
directly plastered faces (front or rear) are not correctly installed as to ensure
proper operation with any type of gas fire. In some instances of this flue
construction, temperature cracking of surface plaster may occur through no
fault of the appliance. An air gap or some form of insulation material should
be installed to prevent normal flue temperatures from damaging wall
surfaces.
1.9 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 125 box).
The box must have a minimum flue diameter of 125mm internal and minimum
internal dimensions of 160mm deep by 490mm high by 350mm wide. There are
no maximum dimensional requirements for the box. 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.
8

1.10 WALL / HEARTH OUNTING
This appliance must be fitted on a flat, non-combustible base of minimum
thickness 12mm. In addition, a non-combustible hearth or physical barrier should
be provided in front of the fire.
With “hole in the wall” type installations, where it may be desirable not to fit a
hearth panel or physical barrier, the product may be installed in accordance with
Document J of the building regulations so that every part of theflame or
incandescent material is at least 225mm above the floor level. For the customers
safety, and in accordance with BS 5871-2, the fitting of a hearth panel or physical
barrier should be carried out. Should this advice not be followed however, please
give consideration to the safety of the occupants in the room to which the
appliance is installed.
Any hearth panel or physical barrier that is fitted should project a mnimum of
300mm forwards from the fire opening and 150mm either side of the fire
opening, as shown below in figure 3. Any physical barrier must be securely fixed
and be of robust design.
Fig. 3
9
Example of Wall
Mounted hysical /
Tactile Barrier
Example of Floor Mounted
hysical Barrier i.e. Hearth
anel
Fireplace Opening
300mm
Minimum
300mm
Minimum
150mm Minimum each
side of fireplace
opening

1.11 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 :-
1.11.1 The spillage monitoring system must not be adjusted by the installer.
1.11.2 The spillage monitoring system must not be put out of operation.
1.11.3 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.
10

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
1 off Fire box / burner assembly
1 off Boxed ceramic log set (boxed inside combustion chamber)
1 off Installation and user instruction book (combined)
1 off Remote control handset
1 off Guarantee
1 off Fascia
4 off AA batteries
1 off 9V battery
8 off Wallplate fixing screws and rawlplugs
1 off Flue restrictor baffle (for use in brick built chimneys and large diameter
e.g. 175mm flue applications).
1 off Draught diverter cover
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 or Pre-Cast Flue to BS EN 1858
When installing into 125mm (5 inch) diameter lined brick or stone flue, or
insulated pre-fabricated metal flue box to BS 715 / BS EN 1856-2 and
pre-cast flues the restrictor baffle must not be fitted.
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. This product is designed to fit into a
standard set of pre-cast starter blocks, without needing to move the
blocks within the wall cavity. If the customer requires the product to
be fitted at a height which requires modification to the pre-cast flue
system, please consult a structural engineer regarding the re-posi-
tioning of the starter / collection blocks of the pre-cast flue syste,
UNDER NO CIRCU STANCES SHOULD THE FIRE BE RECESSED INTO THE
GATHER BLOCK, OFFSET OR STRAIGHT FLUE BLOCKS.
11

2.3 PREPARATION OF THE FIREBOX OPENING
2.3.1. If installing the product into a hole in the wall type installation, create an
opening as shown in figure 4 below. If installing into a conventional
opening with a hearth panel, create an opening as shown in figure 5
below.
Fig. 4 - Hole in the Wall Installations
Fig. 5 - Conventional Installations
12
Min. 350mm
Max. 400mm
Min. 490mm
Max. 500mm
Asper section 1.6,
1.8or 1.9
Min.350mm
Max. 400mm
Min. 490mm
Max. 500mm
70 Mini u
This will ensure clearance for
the fascia asse bly
50mm
300mm
Minimum
750mm Minimum
100 Mini u
This will ensure that the
distance fro floor level to
the burner is 225 and
hence co plies with
Docu ent J of the building
regulations (paragraph 3.4)
Aspersection 1.6,
1.8 or 1.9

2.3.2 Remove the firebox / burner assembly from the packaging. Remove the
fuel-bed set from the combustion chamber and store in a safe location.
Remove the firebox mounting plate from the rear face of the firebox
assembly by unscrewing the 4 off M5 retaining screws as shown below
in figure 6.
Fig. 6
13

2.3.4 The firebox mounting plate should then be secured to the fireplace
opening as created in section 2.3, via the mounting holes as indicated
below in figure 7.
Fig. 7
2.3.5 Drill minimum of 8 off holes to secure the firebox mounting plate
(14 off holes are provided in the mounting plate to allow a variety of
fixing positions) and secure the firebox mounting plate to the fireplace
opening. Use a minimum of eight fixing points to ensure a satisfactory
seal is achieved. It may be necessary to seal the plate with suitable
tape if required.
2.3.6 Remove the burner unit from the fire as shown overpage in figure 8.
14
610mm
500mm
245
mm
305mm
25mm
12mm Base
Centre Hole
Only
25mm
215mm
430mm

2.3.7 Remove the 6 off screws to remove the burner gauze, then 4 off screws
to remove the ceramic support and finally 4 off burner mounting screws
as shown below in figure 8, then lift the burner unit clear of the firebox.
Fig. 8
2.3.8 With the burner removed from the firebox, plan the routing of the gas
supply pipe into the firebox. See overpage, section 2.3.9 for suggested
pipework routing.
15
Burner unit -
held in position
by 4 off securing
screws
Burner gauze -
held in position by
6 off screws
Creramic support -
held in position by
4 off securing
screws

Continue for all models
2.3.9 Decide which side the gas supply is to enter the fire from. 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 figure 9 & 10 below for
suggested pipe layouts.
Fig. 9
Fig. 10
Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound.
2.3.10 Carefully withdraw the fire box from the opening to enable the gas
supply and fire fixing to be completed.
16
Firebox
Fireplace
Builders
Opening
Gas Supply
Firebox
Approx.
40mm Fireplace
Gas Supply
Approx.
40mm

2.3.11 With the fire securely in place, if a concealed gas connection has been
made through the access holes in the rear of the fire, the
holes should be closed around the pipe with the grommet supplied to
prevent leakage of air through the gap around the pipe, failure to do
may lead to flame reversal, which will invalidate the guarantee.
2.3.12 Refit the burner. Fit the four retaining screws and check that the
burner is correctly locked into position.
2.3.13 Secure the firebox into the mounting plate with the four off M5 screws.
2.3.14 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.
2.4 GAS TIGHTNESS AND INLET PRESSURE
2.4.1 Remove the pressure test point screw from the inlet elbow and fit a
manometer.
2.4.2 Turn on the main gas supply and carry out a gas tightness test.
2.4.3 Light the fire, see page 24-25 for full details of the operating method
for the fire.
2.4.4 Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.)
2.4.5 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.
17

SECTION 3
ASSE BLING FUEL BED AND CO ISSIONING
3.1 ASSE BLING THE CERA ICS AND FUEL BED
3.1.1 Place the fuel-bed front ceramic fibre as shown below in figure 11.
Fig. 11
3.1.2 Place the left hand and right hand front ceramic fibre pieces as shown
below in figure 12.
Fig. 12
18
NOTE : The position of the fuel-bed co ponents are critical to the
perfor ance of the product. Therefore please ensure that the fuel-bed
co ponents are positioned as described in the following section prior to
requesting a service call due to soot build up, poor fla e pattern etc.
Front ceramic fibre
Left and right hand front ceramic fibres

3.1.3 Place a single layer of bark chippings over the burner as shown below
in figure 13.
Fig. 13
3.1.4 Fit the rear base log as shown below in figure 14.
Fig. 14
19
Rear log

3.1.5 Fit log A as shown below in figure 15, onto the rear log.
Fig. 15
3.1.6 Fit log B as shown below in figure 16, onto the rear log.
Fig. 16
20
Log A
Log B