Flavel FRDC**MN Series User manual

enilworth
&
Linear Coal
DECORATIVE FUEL EFFECT GAS FIRE
Installation and Maintenance Instructions
Hand these instructions to the user
Model o. FRDC**M is for use on atural Gas (G20) at a supply
pressure of 20 mbar in G.B. / I.E.

CO TE TS
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 Fire place opening / catchment space 6-7
1.7 Fitting to Pre-Cast 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 fire box 10-16
2.3 Gas tightness and inlet pressure 17
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 18-21
3.2 Lighting the appliance 22
3.3 Checking for clearance of combustion 22-23
products
Section 4 Maintenance
4.1 Removal of the Burner Assembly 24
4.2 Removal of the Piezo Igniter 24
4.3 Removal of the Control Tap 25
4.4 Removal of the Pilot Assembly 25
This appliance is manufactured by:-
BFM Europe Ltd,
Trentham Lakes,
Stoke-on-Trent, ST4 4TJ
2

SECTIO 1
I FORMATIO A D REQUIREME TS
1.0 APPLIA CE I FORMATIO
Model FRDC**MN (** denotes trim / fret variant)
Gas Type G20
Main injectors (2 off) Size 260
Pilot Type Copreci Single Flame 21100 / 141
Max. Gross Heat Input : 6.9 kW
Min. Gross Heat Input : 4.2 kW
Cold Pressure : 20.0 +/-1.0 mbar
Ignition : Push-button Piezo
Electrode Spark Gap 4.5mm
Packed Weight 18.5 kg Brass, 16.5 kg Black
15.0 kg Linear models
Fire box Dimensions (with trim fitted)
Width : (with standard trim, no spacer) 470mm
Height : (with standard trim, no spacer) 586mm
Width : (with linear trim, no spacer) 484mm
Height : (with linear trim, no spacer) 595mm
Depth : (overall-without fender) 170mm
Depth : Flush-fit (from mounting face to rear) 170mm
Depth : Flush-fit (mounting face to rear 120mm
with 50mm spacer fitted)
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2002 and the result is 48%.
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

I STALLATIO REQUIREME TS
1.1 CO DITIO S OF I STALLATIO
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 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. 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)
o purpose made additional ventilation is normally required for this appli-
ance, 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 ational
Standards Authority of Ireland. If installing in orthern 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 A D CHIM EY 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.
Minimum diameter of circular flues 125 mm (Without Flue
Restrictor Fitted)
Minimum effective height of all flue types 3 metres
When fitting to conventional chimneys or 175mm flues it may be desirable to
leave the flue restrictor baffle (supplied) in place 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 / SURROU D 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 150˚c.
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 POSITIO
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 / CHIM EY I SPECTIO
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 FIRE PLACE OPE I G A D CHIM EY CATCHME T SPACE
The front opening of the fire place must be between 375 and 440 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
375mm Minimum
440mm Maximum
610mm
Minimum
490mm Minimum
Fig. 1
550mm Minimum
570mm Maximum
Minimum Flat
Sealing Area
6

Table A - Installation Dept Requirements for a Flavel Kenilwort / Linear
Coal being installed into a brick built c imney, requiring 12.0 litres of debris
collection volume (fig. 2).
When installing this product into a builders opening / brick-built chimney, the depth
required is a minimum of 170mm. The 12.0 litres of debris collection volume is
achieved by the space available taper down the sides of the firebox. This depth
can be reduced to 120mm if the black 50mm spacer frame is used. This spacer
frame can be purchased from BFM Europe Ltd. as an optional extra.
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 260mm. If the depth is less than 260mm then the spacer
(optional) must be used to give a minimum clearance from the rear of the fire to
the rear of the chairbrick of at least 90mm to allow sufficient space for the
collection of debris which may fall down the chimney. 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 400mm wide opening (without
a chairbrick), the depth required would be 170mm. See fig. 2 below for
explanatory diagram.
Fig. 2
7
Opening Widt ( e.g. 400mm)
Dept Required
(e.g. 170mm)

1.7 FITTI G TO PRE-CAST FLUE I STALLATIO S
When installing this appliance into pre-cast flues, always ensure that the
spigot restrictor baffle has been removed.
To install the fire box in to pre-cast flue starter blocks, there must be at least
170mm 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 170 mm to the rear of
the starter block, otherwise there will be insufficient depth. To increase this depth
the optional black 50mm spacer frame may be purchased, this will reduce the
depth required to 120mm or 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 Flavel Fires for advice before
proceeding. This fire has been designed to fit standard 100mm pre-cast
starter blocks with 3 inch rebated surrounds.
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 E 1858. In accordance with BS E 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.
1.8 FITTI G TO PRE-FABRICATED TWI WALL METAL 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 580mm 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.
1.9 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.
8

1.10 SPILLAGE MO ITORI G SYSTEM
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 combus-
tion products in the room in which the fire is operated. The following are impor-
tant 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

SECTIO 2
I STALLATIO OF FIRE
2.1 U PACKI G 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 fuelbed base, ceramic front rail and 18 coals (16 large, 2 small)
1off Loose items bag.
1off Cable Fixing it
1off Trim & Fender or Linear Trim & ashpan cover (dependent upon model
selected)
1off each User instruction book and Installation book
2.2 I STALLI G 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 B.S. 715, or pre-cast flues to BS E 1858
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.
10

Proceed as follows :-
a) Remove the trim / fret. Remove the burner heat shield from the front of
the fire box to allow access to the burner. See fig. 3 below.
Fig. 3
b) Ensure that the hearth is protected from damage and carefully lift the
fire box into the fire opening, then slide it back into position. Check that
the fire box flange fits flush to the sealing face of the fire surround or
wall with no gaps present.
c) Remove the four retaining screws securing the burner to the firebox.
The base of the burner unit can now be pulled forward, allowing the
burner to be removed from the fire box. See fig. 4 below.
Fig. 4
11

d) 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. 5a & 5b below for
suggested concealed pipe layouts.
Fig. 5a
Fig. 5b
ote : 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.
12
Firebox
Approx.
40mm Fireplace
Gas Supply
Firebox
Approx.
40mm Fireplace
Gas Supply

IMPORTA T : Sealing of the Gas Unused Gas Pipe Inlet Apertures
In line with current CORGI regulations, it is imperative that the gas supply inlet
apertures 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. 6 below shows a correctly sealed installation.
Fig. 6
PLEASE NOTE :-
Only oles to be left are t e specifically
sized air relief oles as indicated by t e
labels positioned by t em and t e gas
inlet aperture t at is used
Seal off unused gas inlet
apertures and cable fixing
oles as s own
BFM EUROPE LTD. WILL OT BE LIABLE FOR
GUARA TEE CLAIMS THAT ARE AS A DIRECT
RESULT OF THE U USED GAS I LET APERTURES
OT BEI G CORRECTLY SEALED.
13

There is a choice of methods of fixing the firebox which are provided to enable the
installer to deal with any type of installation.
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.
The fire may be secured using the cable method as described below, or alterna-
tively, in installations where the cable method is not suitable (eg. loose masonary
in rear of fire opening) the fire box may be secured to the fire surround using
suitable screws and rawlplugs (not provided). The foam seal (supplied) must be
fitted around the perimeter of the firebox in a “goalpost” arrangement to ensure a
seal is achieved to the fireplace.
To fit using the preferred cable method proceed as follows-
e) Mark out and drill 4 off No 14 (7mm) holes in the back face of the fire
opening in the positions shown below in fig. 7
Fig. 7
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.
f) 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.
14
Fireplace Opening
325mm
100mm
500mm
20mm

g) 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.
h) 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).
i) 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. 8 below
Fig. 8
j) 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.
k) With the fire securely in place, if a concealed gas connection has been
made through either of the access holes in the sides or rear of the fire,
the holes should be closed around the pipe to prevent leakage of air
through the gap around the pipe.
l) Refit the burner. Fit the four retaining screws and check that the burner
is correctly locked into position.
15

m) Refit the front burner heat shield to the sides of the fire box (2 Screws)
and secure the trim to the fire using the magnets provided.
n) 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.9) is a diagram to indicate the hole centre
positions available on the firebox to facilitate the screw fixing to the fireplace /
surround.
Fig. 9
260mm
37mm
532mm
425mm
Firebox
Mounting
Flange
16

2.3 GAS TIGHT ESS A D I LET 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 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 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.
17

SECTIO 3
ASSEMBLI G FUEL BED A D COMMISSIO I G
3.1 ASSEMBLI G THE CERAMICS A D FUEL BED
a) Place the ribbed ceramic fuelbed base on top of the fuelbed support
and pull fully forwards to the burner. Make 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. See fig. 10 below.
Fig. 10
b) Position the two halves of the front ceramic (L/H & R/H) on the locating
channel in the front ceramic, ensuring it is located onto the lip on the
burner front ceramic support. (See fig. 11 below)
Fig. 11
18
NOTE : The position of the fuel-bed components are critical to the
performance of the product. Therefore please ensure that the fuel-bed
components are positioned as described in the following section prior to
requesting a service call due to soot build up, poor flame pattern etc.

c) Fit five of the large sized coals onto the front ceramic rail, ensuring
that they are evenly spaced. Use the recess’s in the front ceramic rail
as a guide for placement. (See fig. 12 below)
Fig. 12
d) Select four of the large coals and arrange behind the front row of coals,
ensuring that flame paths as indicated below are not interupted.
. (See fig. 13 below)
Fig. 13
19

e) Select three of the large coals and arrange along the rear of the
fuelbed, using the ribs in the rear of the fuelbed as a guide for
placement. (See fig. 14 below)
Fig. 14
f) Select the two small coals and position to fill the gaps at each end of
the third row of coals, as shown. Fig. 15
Fig. 15
20