Flavel Curve User manual

Curve
RADIANT FLA E EFFECT GAS FIRE
Installation and aintenance Instructions
Hand these instructions to the user
odel No’s FCRR**RN is for use on Natural Gas (G20) at a supply
pressure of 20 mbar in G.B. / I.E.
NB: “**” refers to fascia 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
1.6 Chimney opening / catchment space 6-7
1.7 Precast Flues 8
1.8 Metal Flue boxes 8
1.9 Hearths 8
1.10 Spillage Monitoring System 9
Section 2 Installation of Fire
2.1 Unpacking the fire 10
2.2 Installing the combustion chamber & closure plate 10
2.3 Preparation of the flue opening 11-13
2.4 Fitting the batteries to the receiver unit 14
2.5 Gas tightness and inlet pressure 15
2.6 Removal of the controls cover 15
Section 3 Assembling Fuel Bed and Commissioning
3.1 Lighting the appliance 16-17
3.2 Checking for clearance of combustion 18
products
3.3 Fixing the “Curve” Fascia in position 19
3.4 Removal & re-fitting of the glass frame assembly 20
Section 4 aintenance
4.1 Removal of the Burner Assembly 21
4.2 Removal of the Valve / Solenoid 21-22
4.3 Removal of the Pilot Assy. 22
4.4 Removal of the RF Receiver / Battery Pack 22
Parts Shortlist 23
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 FCRR**RN “**” denotes fascia variant
Gas Type G20
Main injectors (1 off) Size 380
Pilot Type Copreci
21100 / 141
Max. Gross Heat Input : 6.5 kW
Min. Gross Heat Input : 3.5 kW
Cold Pressure : 20.0 +/-1.0 mbar
Ignition : 9V Battery Generator
Electrode Spark Gap : 4.5 Nominal
Weight : 32 kg
Fire box Dimensions (with & without fascia’s fitted)
Width : (with fascia fitted) 890mm
Height : (with fascia fitted) 650mm
Projection from wall : (overall-without fascia fitted) 130mm
Projection from wall : (overall-with fascia fitted) 146mm
Gas Connection : 8mm Compression (Supplied with fire)
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2002 and the result is 64%.
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 CORGI 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. B.S. 5871 Part 1 Installation of Radiant Convector Gas Fires
2. B.S. 6891 Installation of Gas Pipework
3. B.S. 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. B.S. 1251 Open fire place components
5. B.S. 715 Metal flue pipes for gas appliances
6. B.S. 6461 Part 1 Installation of Chimneys and flues
7. B.S. E.N. 1858 Chinmeys Components & Concrete Flue Blocks
8. I.S. 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. It is also suitable for use with pre-cast flue blocks conforming
to BS EN 1858 and metal flue boxes conforming to BS 715. All flues must
conform to the following minimum dimensions.
inimum diameter of circular flues 125 mm
inimum effective height of all flue types 3 metres
Safe clearance of products must always be checked by carrying out a smoke
match test as described.
4

1.3 FIREPLACE / SURROUND SUITABILITY
This fire can be installed with a fire surround in a conventional type installation
(see page 11 for dimensional information) or without a fire surround, for a hang on
the wall type installation. It must not be installed directly onto carpet or other
combustible floor materials.
The fire surround if installed must be manufactured from non-combustible
material and have 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 Imagination fascia. Soft wall coverings such as blown vinyl, wall paper
etc. will be affected by the rising hot air and scorching and / or discoloration
will 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 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
chimney / 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 CHI NEY OPENING AND CATCH ENT SPACE
The front opening of the chimney must be between 300mm and 440mm wide, and
between 300mm and 440mm high. If the opening exceeds these dimensions then
an opening must be constructed from suitable non-combustible material to
produce a correct size opening. Any opening must be suitably sealed 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
300mm Minimum
440mm Maximum
Fig. 1
300mm Minimum
440mm Maximum
Minimum Flat
Sealing Area
10mm all round
6
460mm
Minimum
460mm Minimum

Table A - Installation Depth Requi ements fo a Flavel Cu ve being installed
into a b ick built chimney, equi ing 12.0 lit es of deb is collection volume
(fig. 2).
When installing this product into a builders opening / brick-built chimney, the depth
required is a minimum of 156mm. The 12.0 litres of debris collection volume is
achieved by the space available below the flue spigot.
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 exceeds 206mm. If the depth is less than 206mm then the chairbrick
must be removed. 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.
For example, if the appliance was to be fitted into a 300mm wide opening, the
depth required would be 156mm. See fig. 2 below for explanatory diagram.
Fig. 2
7
Opening Width ( e.g. 300mm)
Depth Required 156mm
minimum for a brickbuilt chimney
Rear face of fireplace
opening
Spigot
Closure Plate
Side View
Plan View

1.7 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 when choosing a fire surround as the thickness of the fire
surround must be sufficient to give a total depth of at least 100 mm to the rear of
the starter block, otherwise there will be insufficient depth. 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. IF FITTING TO A PRE-CAST FLUE SYSTE , ALWAYS RE OVE THE
FLUE RESTRICTOR PLATE.
1.8 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 100mm deep by 300mm high by 300mm 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.
1.9 HEARTHS (IF SPECIFIED)
If fitting without a hearth panel, this appliance must only be installed at a minimum
height to the base of the opening of 160mm above the floor level, (measured from
the bottom edge of the “Curve” fascia) e.g. above the level of the carpet or floor
covering.
If fitted using a conventional hearth panel, the distance from the top face of the
hearth panel to the bottom of opening / closure plate should be a minimum of
100mm
8

1.10 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.
9

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 Combustion chamber and glass frame assembly
1 off Loose items bag including :-
1 off Remote control handset
4off AA Batteries
1 off 6mm Allen key
1 off each User instruction book and Installation book
1 off Curve Fascia
1 off Closure Plate
2.2 INSTALLING THE CO BUSTION CHA BER & CLOSURE PLATE
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, or insulated pre-fabricated
metal flue box to B.S. 715.
When installing into 125mm (5 inch) diameter lined brick or stone flue, or
insulated pre-fabricated metal flue box to B.S. 715 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.
PLEASE NOTE :- IF INSTALLING THIS PRODUCT INTO A HOLE IN THE WALL
TYPE INSTALLATION IN WHICH THE FLUE TYPE IS PRE-CAST, SPECIALIST
ADVICE UST BE OBTAINED FRO A STRUCTURAL ENGINEER
REGARDING THE RE-POSITIONING OF THE STARTER BLOCKS.
UNDER NO CIRCU STANCES SHOULD THE FIRE BE RECESSED INTO THE
GATHER BLOCK, OFFSET OR STRAIGHT FLUE BLOCKS.
10

2.3 PREPARATION OF THE FLUE OPENING
If installing the product into a wall mounted installation, create an opening as
shown in Fig. 3 below. If installing into a conventional opening with a hearth
panel, create an opening as shown in Fig. 4 below.
Fig. 3 - Wall ounted Installations
Fig. 4 - Conventional Installations
Minmum225mm
Min. 300mm
Max. 440mm
Min. 300mm
Max. 440mm
Min. 300mm
Max. 440mm
Min. 300mm
Max. 440mm
100mm Minimum
50mm
300mm
Minimum
11
760mm Minimum
Minimum Depth 156mm
for brick built chimneys,
100mm for pre-cast flues
& pre-fabricated flues
Minimum Depth 156mm
for brick built chimneys,
100mm for pre-cast flues
& pre-fabricated flues

Proceed as follows :-
a) Prepare the mounting holes on the wall to which the fire is to be
fitted. See Fig. 5 below.
Fig. 5
b) Centre the closure plate around the fireplace opening and mark the
positions of the mounting holes as shown above in fig. 5
c) Remove the closure plate and drill suitable holes to suit the method of
fixing to the wall.
Please Note : Due to the varying wall conditions encountered, fixings
are not supplied with the product.
d) Decide which side the gas supply is to enter the fire from. If concealed
pipe work is required plan the pipe run to enter from behind the
closure plate. This will require a cut out in the closure plate itself, or a
suitable hole creating in the plasterboard / brickwork below the edge of
the fire. See Fig. 6 overpage for diagram to relate the position of the
gas inlet / restrictor elbow to the closure plate supplied. The gas
connection to the appliance should be made to the isolating / inlet elbow
using 8mm rigid tubing.
e) Re-position closure plate and seal to the wall with suitable tape.
f) The combustion chamber can then be mounted to the wall via the holes
as detailed in section c).
12
Spigot
Fire Opening
C/L
Closure Plate
34mm
550mm CRS
Mounting holes for combustion chamber
Diameter
6mm

Fig. 6
Note : Before breaking into the gas supply a tightness test should be carried
out to establish that the existing pipework is sound.
g) 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.
13
Spigot
Fire Opening
C/L
Closure Plate
Gas Supply
Restrictor / PTP
Elbow
460mm
128mm

2.4 FITTING THE BATTERIES TO THE RECEIVER UNIT
a) 4 off AA 1.5V batteries (found in the loose items pack) are to be fitted to
the battery holder located centrally on the fire, below the combustion
chamber as shown below in Fig. 7.
Fig. 7
b) To remove the receiver unit, firstly loosen the retaining screw that holds
the unit in place.
c) Slide off the cover from the reciever unit.
d) Fit the 4 off AA batteries to the unit as shown in Fig. 8 and refit the
cover.
Fig. 8
e) Re-fit the receiver unit into it’s holder and tighten the retaining screw (do
not over-tighten as this may damage the unit). Take care not to trap or
damage any wires to the unit.
14
Receiver Unit
Receiver Unit
retaining screw

2.5 GAS TIGHTNESS AND INLET PRESSURE
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 15 / 16
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.
2.6 RE OVAL OF THE CONTROLS COVER
a) The controls cover is located on the left hand side of the product (when
viewed from the front). The cover is removed by gently lifting away in a
vertical direction as shown below in Fig. 9, to reveal the control valve as
shown in Fig. 10
Fig. 9 Fig. 10
b) To re-fit the controls cover, locate in the slot and clip and fit back in
position.
15
Lift controls
cover
vertically
away
Control valve

SECTION 3
CO ISSIONING OF THE FIRE
3.1 LIGHTING THE APPLIANCE
a) The control valve is positioned on the left hand side of the fire when
viewed from the front.
b) To operate the appliance automatically via the remote control handset,
ensure that the on / off switch is switched to the “on” position as shown
below in Fig. 11
Fig. 11
c) Switch the MANUAL control disc to the “on” position. (Image above
shows “MANUAL” control disc set in the “MAN” position).
d) Switch the main valve knob to the “OFF” position. (Image above shows
“MAIN VALVE” knob set in the “OFF” position.
e) Press and hold the “STAR” button and “UP” button on the remote hand
set simultaneously, see Fig. 12 overpage for image of handset.
f) The valve will then emit an audible beep and commence its ignition
sequence. When the pilot flame has been established, the control will
continue to beep whilst the thermocouple heats up. When the
thermocouple has reached operating temperature, it will allow gas to
flow to the burner and the burner will light at high rate heat input
(6.5kW).
16
On / Off Switch
“MA UAL”
Control Disk
“MAI VALVE” Knob

Fig. 12
g) The fire can now be switched between HIGH rate heat input and LOW
rate heat input by pressing the “DOWN” arrow on the handset. To
reduce the flame height of the main burner incrementally, press the
arrow momentarily. To reduce the heat input directly down to the mini
mum level, press the “SMALL” flame arrow on the handset twice,
NOTE : The flame will go to HIGH rate heat input before going to
designated LOW rate heat input. To return back to HIGH rate heat input
press the “LARGE” flame button twice. To put the fire in In “STANDBY
MODE” (only the pilot remains lit) press and hold the “SMALL” flame
arrow on the handset.
AFTER THE PILOT FLA E HAS BEEN EXTINGUISHED, IF YOU
WISH TO RE-LIGHT THE APPLIANCE YOU UST WAIT AT LEAST
THREE INUTES BEFORE TRYING TO RE-LIGHT THE FIRE.
h) Should the handset be misplaced, you can turn the fire off by switching
the “ON / OFF” switch to the “OFF” position.
17
“STAR” / “OFF” button
“UP” button
“DOW ” / “STA DBY”
button
“LED” handset light

3.2 CHECKING FOR CLEARANCE OF CO BUSTION PRODUCTS
a) Close all doors and windows in the room.
b) Light the fire and allow to run for approximately 5 minutes on high
position.
c) After approximately 5 minutes hold a smoke match as shown at the
lower front edge of the draught divereter, as shown below in Fig. 13
It is recommended that a suitable smoke match holder is used when
checking for clearance of combustion products. All smoke generated
should be drawn back into the flue. If slight spillage occurs or if in
doubt, repeat the test after a further 5-10 minutes.
d) If spillage persists, remove the flue restrictor baffle from the spigot by
removing the spigot itself, the two top screws secure the restrictor baffle
and spigot to the rear of the combustion chamber. If after removing the
flue restrictor baffle spillage still persists, the flue is not functioning
correctly and a fault exists. If, after investigation the fault cannot be
traced and rectified, the fire must be disconnected from the gas supply
and expert advice obtained.
e) If there is an extractor fan fitted any where in the vicinity of the
appliance, the spillage test should be repeated with the fan running on
maximum and all interconnecting doors open.
f) 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.
Fig. 13
Smoke Match Position - Just below and inside the
lower edge at the center of the draught diverter,
above the glass frame
18

3.3 FITTING THE “CURVE” FASCIA
a) The “Curve” fascia is fitted to the product by hooking the top edge of
the fascia over the mounting brackets as shown in Fig. 14 below, then
securing with two screws on the bottom face of the trim as shown in
Fig. 15 below.
Fig. 14
Fig. 15
Align mounting bracket on “Curve”
fascia with mounting bracket on
combustion chamber and fix with
screws supplied
Image viewed from
underside of trim
Hook “Curve”
fascia onto top
mounting brackets
19

3.4 RE OVAL & RE-FITTING OF THE GLASS FRA E & PANEL
a) Remove the “Curve” fascia by unscrewing the retaining screws and
lifting the “Curve” fascia off the brackets, in the reverse order as
detailed in section 3.3, on page 18
b) The glass frame is then removed by using the 6mm allen key supplied
to unscrew the 4 off allen bolts (Fig. 16) and lifting the glass frame /
panel clear.
Fig. 16
c) To re-fit the glass panel / frame, re-assemble in reverse order.
d) Replace the allen key supplied in its location slot at the bottom
right hand side of the combustion chamber.
The ceramic fibre back used in this product is manuafctured from R.C.F
(Refractory Ceramic Fibre) To ensure that the release of fibres from this item
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.
20
4 off 6mm Glass
Frame Retaining
Allen Bolts