Flavel Emberglow User manual

Emberglow
COAL EFFECT BALANCED FLUE GAS FIRE
Installation and aintenance Instructions
Hand these instructions to the user
odel No’s FEBC00 N is for use on Natural Gas (G20) at a
supply pressure of 20 mbar in G.B. / I.E.

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 Preparation of the wall 7
2.3 Preparation of the flue hole 8
2.4 Preparation of the flue pipes 9
2.5 Installation of the gas supply 10-11
2.6 Securing of the combustion chamber to the wall 11-12
2.7 Fitting the terminal guard 12
2.8 Removal & refitting of the glass frame 13
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the fuel bed 14
3.2 Lighting the appliance 15-16
3.3 Fitting the fender 17
3.4 Fitting the canopy 17
Section 4 aintenance
4.1 Removal of the Burner Assembly 18
4.2 Removal of the Control Valve 18-19
4.3 Removal of the Battery Pack 19
4.4 Removal of the Pilot Assembly 19
4.5 Removal of the Touch Control Switch 19-20
The model no. of this appliance is on the rating plate, which is affixed to the
battery pack retaining bracket on the front right hand side of the fire. The product
is manufactured by:-
BFM Europe Ltd, Trentham Lakes, Stoke-on-Trent, Staffordshire, ST4 4TJ
2

SECTION 1
INFOR ATION AND REQUIRE ENTS
1.0 APPLIANCE INFOR ATION
Main injector : (1 off) Bray Injector Elbow – size 360
Pilot Type : S.I.T.140 Series G – size 27
Max. Gross Heat Input : 5.25 kW
Min. Gross Heat Input : 2.05 kW
Gas Rate : 0.470 m3/hr (High)
0.190 m3/hr (Low)
Cold Pressure : 20.0+/-1.0 mbar (8.0 +/- 0.4 in w.g.)
Ignition : Integral to gas valve
Electrode Spark Gap : 4.0mm
Weight (Product & Fender) : 33 kg
Weight (Canopy) : 23 kg
3
673mm
445mm
290mm
198mm
716mm
645mm
Fig 1 -
Product
Dimensions

INSTALLATION REQUIRE ENTS
1.1 CONDITIONS OF INSTALLATION
In Great Britain :-
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
ational 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 3 Installation of Decorative Fuel Effect 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 (Republic of Ireland)
If installing this product into a timber framed building, please consult document
IGE / UP 7, issued by the Institute of Gas Engineers.
In 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 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 propri-
etary 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.
4

1.3 FLUE TER INAL 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
DI ENSION TER INAL POSITION INI U DI ENSION
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)
L From an opening in the car port 1200m (48in)
Vertically from a terminal on the same wall 1500mm(59in)
N Horizontally from a terminal on the 300mm (12in)
same Wall
O NOT APPLICABLE N/A
P NOT APPLICABLE N/A
Q NOT APPLICABLE N/A
5

1.4 SHELF POSITION
The fire may be fitted below a combustible shelf providing there is a minimum dis-
tance 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 level concrete or non-combustible
hearth. The feet must not be removed when installing directly onto a hearth.The
hearth material must be a minimum thickness of 13 mm with the outer perimeter of
the hearth panel at least 50 mm above the floor level, to discourage the placing of
carpet or other floor coverings over it. The hearth must be fitted symmetrically
about the fire opening and have a minimum width of 760 mm and a minimum
projection of 350 mm forwards from the fire opening.
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 the pack. Check the contents as listed :-
DO NOT UNDER ANY CIRCU STANCES USE THIS APPLIANCE IF THE
GLASS PANEL IS BROKEN OR NOT SECURELY FIXED TO THE FIREBOX.
Packing Check List
Pack 1 of 1
1off Combustion chamber / burner assembly
1off 2 piece fuel-bed set (packed in seperate carton)
1off Flue pipe and flue terminal unit
1off Installation & Maintenance Instruction Book
1off User Instruction Book
1off Loose items pack
1off Cooler plate
2off Brass finials - to be screwed into casting upon commisioning
2off Decorative side trims & 4 off side trim fixing screws
Pack 2 of 2
1off Cast iron canopy assembly
6

2.2 PREPARATION OF THE WALL
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, and
the hearth size conforms to the requirements of section 1.5 on page 6.
The minimum height from the floor to the centre of the flue is shown on fig. 3
below.
A min / max sized opening with a flat rear face between the fire opening and flue
outlet terminal is shown below. (fig 4).
7
Minimum Cavity Depth
150mm. Maximum Flue
Length 680mm
Combustion Chamber
Outer Wall
Flue Terminal
420mm to centre
line of flue from
hearth level
153mm
Hearth
Fig. 4
Fig. 3

2.3 PREPARATION OF THE FLUE HOLE
a) Mark the position of the centre of the flue on the inner wall.
b) Cut hole for outer flue pipe. There are two possible methods to achieve
this, either core drill or via hammer and chisel.
c) To core drill, proceed as follows :-
Drill a pilot hole through the wall, in position as specified in figure 4.
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 4.
Mark the position of the hole around this point.
Chisel out the area as marked on the wall.
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 as specified on page 7.
Prior to installing the combustion chamber and flue pipe assembly, ensure the
decorative side trims are secured with the screws as shown below in Fig. 5 a
Fig. 5a
8
Decorative Side
Trims screw to side
panel of fire with
screws provided

2.4 PREPARATION OF THE FLUE PIPES
a) Measure the wall thickness and add on 110mm, to give the correct
length of the flue.
b) Mark this dimension onto the flue pipe, measuring from the end at
which the terminal is located.
c) Cut off surplus flue length that is not required, and remove any burrs
from the edges with a burr knife or file.
d) Push the flue pipe / terminal assembly firmly into the rear of the
combustion chamber as shown below in Fig. 5a, ensuring that the flue
pipe flange is at the top.
e) Drill 3 off holes, through outer flue pipe and into the mounting spigot,
and screw flue pipe and terminal assembly into place, as shown below
in Fig. 5b
Fig. 5b
I PORTANT : DO NOT CUT FLANGED ENDS OF FLUE PIPE & ENSURE THE
PIPES ARE CUT SQUARELY.
f) Using mortar or sealing compound, seal the outer flue pipe to the out
side surface of the wall, (See Fig. 6 for position of mortar).
9
3 off holes to be drilled
into spigot ring and 3 off
screws to be used to
secure flue pipe to
spigot ring.
Seal around flange with foil
tape supplied
IMPO TANT NOTE : THE FLANGE SEAL OF THE FLUE PIPE ASSEMBLY MUST
BE MOUNTED AT THE TOP OF THE FLUE PIPE
FLANGE
OF PIPE
TO BE AT
TOP

Fig. 6
2.5 INSTALLATION OF THE GAS SUPPLY
a) An 8mm restrictor elbow is supplied fitted to the product for the
connection of the gas supply. This elbow is situated on the right hand
side of the product when viewed from the front. It is therefore suitable
for rear or right hand side gas supply. See Fig. 7 below.
Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound.
10
ear gas
supply route
Position of
Mortar or Fire
Cement Seal
around Flue
terminal
ight hand
gas supply
route
Left hand
gas supply
route
Pressure Test Point and
estrictor elbow
connection point located
at the bottom /H side
of the appliance
Flue terminal
Combustion
Chambe
viewed f om top
Fig. 7

b) 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.
c) The gas connection should be made to the appliance inlet elbow to
using 8mm rigid tubing.
d) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
e) Turn on the main gas supply and carry out a gas tightness test.
f) To light the appliance, refer to section 3.2 on pages 15 to 17.
NOTE : Please ensure that the battery that has been disconnected at the factory prior
to packing is re-connected. The battery is located at the bottom L/H/S of the
combustion chamber, attach the flying lead to it
g) Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.)
h) 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 SECURING OF THE CO BUSTION CHA BER TO THE WALL
a) The combustion chamber should be secured to the wall using the
4 off screws and rawlplugs provided. Drill 4 off 6.0mm diameter holes
into the wall behind the product as shown below in Fig. 8
11
463mm
Dimensions from top
face of the hearth
panel to centre of
mounting holes
6 inch / 150mm core
drilled hole to suit
the flue pipes at
420mm height
Fig. 8 495mm
75mm

b) Fit the rawlplugs into the 6mm holes.
c) Clip the cooler plate into the bottom central fixing and into the left hand
and right hand mouning brackets (the same brackets used in section d)
below)
d) The mounting brackets are attached to the rear of the combustion
chamber, position the product against the mounting wall and using a
long philips screwdriver, secure the 2 off screws into the wall behind the
product.
NOTE : In England & Wales, the 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. BF Europe also recommend the
fitting of a flue terminal guard where regulations do not demand that it be
fitted. A suitable flue terminal guard can be obtained from BF Europe Ltd.
quoting part no. 70-46560
2.7 FITTING THE OPTIONAL EXTRA TER INAL GUARD
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. Remove the terminal
guard and drill the 4 off 6 mm holes. Insert the rawl plugs into the drilled holes,
replace the terminal guard over the top of the flue terminal and attach to the wall
using the o.12 x 40mm screws provided with the terminal guard. See Fig. 9
below.
Fig. 9
12

2.8 RE OVING / RE-FITTING THE GLASS FRA E ASSE BLY
a) The glass frame is held in position by hooking the top flange over the
combustion chamber opening at the top as shown in Fig. 10 below.
Fig. 10
b) The assembly is then secured to the bottom of the combustion chamber
by the two hinge clamp brackets as shown below in Fig. 11. These are
clamped together to form the seal between the glass frame assembly
and the combustion chamber.
NOTE : Always ensure that a consistent seal between the combustion
chamber and the glass frame is achieved.
Fig. 11
13
Glass Frame Assembly
locates over lip on top of
combustion chamber lid, and
drops onto flange as shown.
To remove, unclip base clips
as shown in Fig. 11 and lift
clear.
denotes correct
final position of
glass frame.
Combustion
Chamber

SECTION 3
ASSE BLING FUEL BED AND CO ISSIONING
3.1 FITTING THE FUELBED
a) Place the fuel-bed rear section centrally in the combustion chamber as
shown below in Fig. 12
Fig. 12
b) Fit the front ceramic coal form in front of the burner, as shown below in
Fig 13. Ensure that the front ceramic coal form is correctly located
behind the retaining brackets at the L/H & R/H ends.
Fig. 13
14
etaining brackets for rear coal form
etaining brackets
for front coal form
NOTE : The position of the fuel-bed components a e c itical to the
pe fo mance of the p oduct. The efo e please ensu e that the fuel-bed
components a e positioned as desc ibed in the following section p io to
equesting a se vice call due to soot build up, poo flame patte n etc.

15
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.

Refit the glass frame as detailed in section 2.8, then light the appliance as detailed
in section 3.2 below.
3.2 LIGHTING THE APPLIANCE
I PORTANT : IF THE BURNER IS EXTINGUISHED FOR ANY REASON YOU UST ENSURE THAT
YOU WAIT A FULL FIVE INUTES BEFORE ATTE PTING TO RE-LIGHT THE FIRE.
Fig. 14
a) Locate the control valve on the appliance, it is situated below the
combustion chamber in the centre. There are two control knobs on the
appliance, the left control knob controls the pilot ignition, the right hand
control knob controls the main burner. This appliance is designed to
run with the pilot permantly running, and the touch control can then be
used to light the main burner, and control the gas rate between high and
low. See Fig. 14 above for layout of controls.
b) Depress the left control knob and rotate it anti-clockwise to the position
marked pilot. (a click will be heard). Hold in the control knob for a few
seconds whilst the air is purged from the supply pipe. Bring the knob
back to its start position and turn it several times to the pilot position.
The pilot should light. Hold in the control knob for at least 10 seconds
to allow the thermocouple to heat up. Release the control knob. If the
pilot fails to light, repeat the procedure as detailed above.
c) Turn the left hand control anticlockwise to the large flame position and
this allows the gas flow to enter the main burner section of the control
valve. The main burner can then be controlled either manually on the
valve or by the touch control switch, located at the bottom of the right
hand side panel.
d) To adjust the heat input manually :-
With the pilot lit as detailed in section c) turn the right hand control knob
anticlockwise to the X position (see Fig. 14 above). This allows gas to
enter the main burner and be ignited by the pilot flame. Once the main
burner has been lit, the right hand control knob can be adjusted to any
position between the large flame (5.45kW heat input) position and the
small flame (2.05kW heat input) position.
16
Pilot
Control
Knob
Main Burner
Control
Knob
X

e) To adjust the heat input via the touch control :-
Press the “up” button to light the main burner and adjust the heat input
to the maximum setting. (5.45kW heat input). Press the “down”
button to reduce the heat input to the minimum setting (2.05kW heat
input). If the low button is pressed and held continuously, the fire
will go pass the minimum setting and extinguish the flames
completely. See Fig. 15 below.
Fig. 15
NOTE : The touch control does not light the pilot, it only lights
the main burner when the pilot flame is established and regulates
the heat input between high and low.
f) Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.) with the main burner operating on “high”.
To turn off the main burner :-
g) Turn right hand control knob clockwise to the position marked
or press the down button on the remote handset until the flame
extinguishes, at this point a clicking noise will be heard from the motor.
To turn off the pilot flame :-
h) Turn left hand control knob clockwise to the position marked
and the pilot flame will extinguish.
i) 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.
17
“Up” button to increase heat
input
“Down” button to decrease
heat input or turn off main
burner

AFTER THE PILOT FLA E HAS BEEN EXTINGUISHED, IF YOU WISH TO RE-LIGHT
THE APPLIANCE YOU UST WAIT AT LEAST FIVE INUTES BEFORE TRYING TO
RE-LIGHT THE APPLIANCE.
WHEN TURNING THE FIRE “OFF” PLEASE ENSURE THAT THE CONTROL VALVE IS
TURNED TO THE “OFF” POSITION AND THE PILOT FLA E IS EXTINGUISHED. DO
NOT LEAVE THE PILOT FLA E ONLY LIT. ENSURE THE ASHPAN COVER IS COOL
BEFORE RE OVING.
Finally, hand the Installation and Maintenance Instructions and the Users
Instructions over to the customer and explain the operation of the fire.
NOTE : THIS APPLIANCE IS DESIGNED TO WORK SAFELY AND EFFECTIVELY
DURING ADVERSE WEATHER CONDITIONS. HOWEVER, DURING SUCH TI ES
FLA E DISTURBANCE AY BE NOTICED. THIS IS NOR AL AND DOES NOT EFFECT
OR I PAIR THE SAFETY OF THE APPLIANCE.
3.3 FITTING OF THE FENDER
Warning : Please take care whilst handling the fender as it’s cast iron
construction means it is a heavy item that can be difficult to manoeuvere
a) Fit the fender by locating the two retaining brackets on the fender into
the slotted channel on the front of the combustion chamber
3.4 FITTING OF THE CANOPY
Warning : Please take care whilst handling the canopy as it’s cast iron
construction means it is a heavy item that can be difficult to manoeuvere
a) The canopy is held in position by two off retaining screws at each side.
b) Fig. 16 below shows the position of the retaining screws for the canopy
Fig. 16
18

SECTION 4
AINTENANCE
Servicing Notes
Servicing should be carried out annually by a competent person such as a
CORGI registered engineer. It is a condition of Flavel Fires 2 year guarantee
scheme that this is carried out by a competent person i.e a CORGI
registered Engineer in accordance with these servicing notes.
The condition of the ceramic coal forms should be checked and if necessary
the whole set should be replaced with a genuine replacement set.
After any servicing work a gas tightness check must always be
carried out.
4.1 Removing the Burner Assembly from the fire.
4.1.1 Isolate the gas supply.
4.1.2 Remove fender from the front of the fire, as described in section 3.3 on
page 17
4.1.3 Remove the glass frame assembly from the fire, as shown in section
2.8 on page 13.
4.1.4 Remove the ceramic coal forms from the combustion chamber
taking care not to damage them.
4.1.5 Remove the two M4 burner retaining screws, located at the front of
each end of the burner.
4.1.6 Slide the burner off the rear injector and remove from the product.
4.2 Removing the Control Valve from the fire.
4.2.1 Isolate the gas supply.
4.2.1 Remove the fender as described in section 3.3, on page 17
4.2.2 Disconnect the pipe to the bulkhead fitting on the valve and disconnect
the pipe on the valve which runs to the inlet elbow.
4.2.3 Loosen the pilot pipe, disconnect the ignition lead from the electrode
and disconnect the thermocouple from the pilot assembly.
4.2.5 Remove the 2 off fixing screws which hold the valve mounting plate to
its mounting bracket and lift the valve and its mounting plate away from
the combustion chamber.
19

4.2.6 Swap the valve mounting plate onto the new valve by unscrewing the
two M5 nuts and bolts holding it in position .
4.2.7 Re-assemble with new valve in reverse order.
4.3 Removing the Battery Pack
4.3.1 Disconnect the wire from the battery pack, located at the bottom
L/H/S of the combustion chamber.
4.3.2 Lift the battery pack out of its mounting cradle.
4.3.3 Re-fit the new battery pack in its cradle and re-fit the wire.
4.4 Removing the Pilot Assembly
4.4.1 Isolate the gas supply
4.4.2 Remove the fender as described in section 3.3, on page 17
4.4.3 Remove the glass frame assembly from the fire, as shown in section
2.8 on page 13.
4.4.4 Remove the ceramic coal forms from the combustion chamber
taking care not to damage them.
4.4.5 Loosen the pilot pipe, disconnect the ignition lead from the electrode,
and remove the thermocouple from the pilot body.
4.4.6 Remove the two fixing screws which secure the pilot assembly to the
pilot mounting panel in the base of the combustion chamber.
4.4.7 Remove the pilot assembly.
4.4.8 Re-assemble with an new pilot assembly, and gasket, ensuring that an
even seal around the pilot assembly is obtained. Carry out a gas
tightness test after re-assembly.
4.5 Replacing the Touch Control Switch
4.5.1 Remove the right hand side panel from the fire. Remove the touch
control switch by releasing the nuts that hold it in position on the inside
face.
4.5.2 Remove the connecting wires from the top left hand side of the
control valve.
20