Flavel FWERN0MN User manual

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WELCOME
RADIANT CONVECTOR GAS FIRE
Installation and Maintenance Instructions
Hand these instructions to the user
Model No’s FWERN0MN & FWERR0MN are for use on Natural Gas
(G20) at a supply pressure of 20 mbar in G.B. / I.E.

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CONTENTS
Contents
Installation Instructions Page
Appliance Data 3
Section 1 1.1 Conditions of Installation. 4
1.2 Flue & Chimney Suitability 4
1.3 Fireplace/Surround Suitability 5
1.4 Shelf Position 5
1.5 Side Clearance 5
1.6 Closure Plate 5
1.7 Flue & Chimney inspection 5-6
1.8 Chimney Catchment space 6
1.8.1 Brick Built Chimney 6-7
1.8.2 Fitting to Pre-Fab. Twin Wall
Metal Flueboxes 7
1.8.3 Fitting to Pre-Cast Flue Installations 8
1.9 Hearth Fitting 8
1.10 Wall Mounting 8
1.11 Spillage Monitoring System 8
Section 2 2.1 Packing Check List 9
2.2 Installation of Fire 9-10
2.3 Gas Connection 11
2.4 Gas Soundness 12
.
Section 3 3.1 Completing the Assembly 12
3.2 Lighting the Appliance 12
3.3 Checking for Clearance of
Combustion Products 13
3.4 Final Checks 14
3.5 Electrical Connection 14
Section 4
Maintenance Instructions
4.1 General Access for Servicing 15
4.1.1 Removal of the Upper Canopy 15-16
4.2 Removal of the Burner Assembly 16-17
4.3 Removal of the Control Tap 18-19
4.4 Removal of the ODS 19
4.5 Removal / Replacement of the Radiants 19
4.6 Removal / Replacement of the lightbulbs 19-20
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APPLIANCE DATA
Main injector (1 off) Bray Elbow size 420, Cat 82
Pilot Type. Copreci Single Flame
Type 21100 / 141
Max. Gross Heat Input : 6.6 kW
Min. Gross Heat Input : 2.0 kW
Cold Pressure : 20.0 +/- 1.0 mbar (8.0 +/- 0.4 in w.g.)
Ignition : Rotary piezo, integral to gas valve
Electrode Spark Gap : 4.0 mm
Weight (Packed) : 21.5 kg
Supply Voltage 230V ac, 50Hz
Fuse Rating 3 Amp
Mains Cable 1 x 1.8M PVC 1mm2
Illumination 2 x 60W BC Fireglow Bulb
Firebox Dimensions (with case fitted)
Width : 715mm
Height : (without feet fitted) 680mm
Depth : 300mm
Height to top of the flue spigot : 420mm
Gas Connection : 8mm compression
(Supplied with fire)
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1.1 CONDITIONS OF INSTALLATION
In Great Britain :-
It is law that all gas appliances are installed only by a CORGI registered installer in
GB, in accordance with these installation instructions and the Gas Safety
(Installation and use) Regulations 1998. 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
relevant recommendations of the following British Standard Code of Practice, and
in accordance with the latest IEE Wiring Regulations.
1. B.S. 5871. Part 1. Installation of Gas Fires.
2. B.S. 5440.: 2000 Parts 1 & 2. Installation of Flues & Ventilation.
3. B.S. 6891. Installation of Gas Pipework.
4. B.S. 6461. Part 1. Installation of Chimneys & Flues.
5. B.S. 1251. Open Fireplace Components.
6. B.S. 715. Metal Flue pipes for Gas Appliances.
7. B.S. 1289 Clay Flue blocks and Terminals.
8. B.S. 7566 Installation of factory-made Chimneys.
Ventilation Requirements
For use in G.B. purpose built ventilation is not normally required for this
appliance.
In Republic of Ireland :-
For use in I.E. this appliance must be installed in accordance with the rules
in force by a competent person and used only in a sufficiently ventilated
space. Please consult document I.S. 813 : 1996 Domestic Gas Installation,
issued by the National Standards Authority of Ireland.
1.2 FLUE AND CHIMNEY SUITABILITY
The appliance is designed for use with conventional brick built chimneys or lined
chimneys and pre – fabricated flues. It is also suitable for use with pre-cast flue
blocks conforming to B.S. 1289 and metal flue boxes conforming to BS 715. All
flues must conform to the following minimum dimensions.
Minimum diameter of circular flues 125 mm
Minimum effective height of all flue types 3 metres
Minimum cross sectional area of Pre-cast Flues 122.7 cm2
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1.3 FIREPLACE / SURROUND SUITABILITY
The fire is suitable for hearth mounting or wall mounting. It must not be fitted
directly onto a carpet or other combustible material. It must not be fitted to
combustible walls.
This fire is suitable for the following hearth / surround types:
Non-combustible hearths / surrounds.
Purpose made proprietary hearths / surrounds with a minimum temperature rating
of 150oC.
If a heating appliance is fitted directly against a wall without the use of a fire-
place or fire surround, soft wall coverings such as wallpaper, blown vinyl,
etc. could be affected by the heat and may, therefore scorch or become dis-
coloured. Please bear this in mind when installing or decorating.
1.4 SHELF POSITION
The fire may be fitted below a combustible shelf providing there is a minimum dis-
tance of 100 mm above the top of the fire and the shelf does not project more than
150 mm. If the shelf overhangs more than 150 mm the distance between the fire
and the shelf must be increased by 25 mm for every 25 mm of additional overhang
over 150 mm.
1.5 SIDE CLEARANCE
A minimum clearance of 100mm should be allowed on either side of the fire for
servicing. Any fire surround uprights should not project forward by more than
100mm.
NOTE. The fire must be installed so that no part of a combustible side wall when
measured laterally is less than 500mm from the radiants.
1.6 CLOSURE PLATE
A closure plate is supplied with this fire and must be fitted. The closure plate must
be sealed to the fireplace or surround opening with suitable adhesive tape. See
section 2.2.2
1.7 FLUE / CHIMNEY INSPECTION
Before commencing installation, a flue or chimney should be inspected to ensure
that all the following conditions are satisfied.
a) Check that the chimney / flue only serves one fireplace and is clear of
any obstruction. Any obstruction. Any dampers or register plates must
be removed or locked in the open position.
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b) Brick / stone built chimneys and 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.
Any under floor air supply to the fireplace must be completely sealed off.
Ensure that the inside of the chimney/flue is in good condition along its 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.
Using a smoke pellet, check that there is a positive up draught present in the
chimney / flue and that the smoke can be seen issuing from the terminal / chimney
pot outside. There must be no leakage of smoke through the structure of the
chimney during or after the smoke pellet test and it is important to check inside
upstairs rooms adjacent to the chimney / flue. Check the chimney pot / terminal
and general condition of the chimney 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 certified flue terminal or cowl suitable for the relevant flue type should be
considered.
A spillage test must always be carried out during commissioning of the
appliance.
1.8 CHIMNEY CATCHMENT SPACE.
1.8.1 Brick Built Chimneys.
The catchment space below the flue spigot should be as deep as
possible, and must not be less than 250mm measured from the bottom
of the flue spigot to the bottom of the catchment space, or to the top of
any “bricking-up” of the fireplace, whichever is the least. See Fig. 1.
The flue spigot must pass through the closure plate at least 25mm and
have a minimum clearance of 50mm between its open end and the
nearest obstruction. There must be a minimum clearance of 165mm
between the back of the closure plate and the back of the catchment
space. See Fig. 1 overpage.
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The front opening of the fireplace must be between 305mm and 440mm
wide, and between 470mm and 650mm high. If the opening is larger
than this, then a surround must be constructed in a suitable non-com
bustible material to create an opening to these limits. Allow a minimum
flat surface of 20mm around the opening to ensure that the closure
plate can be sealed to the fireplace.
Any surround must be sealed to the fireplace to prevent leakage. The
operation of the chimney should be tested a detailed as in section 1.7.
Note. A flue spigot extension of up to a maximum total length of 125mm
may be fitted if necessary, providing that a minimum clearance
50mm between its open end and nearest obstruction is always
maintained.
Fig.1. Chimney Catchment Space.
1.8.2 Fitting to Pre-Fabricated twin wall metal Flue Boxes.
The appliance may be fitted to a twin wall metal flue box 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.
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1.8.3 Fitting to Pre-Cast Flue Installations.
The pre-cast opening must be a minimum of 122.7cm2or
equivalent cross-sectional area and have a minimum effective flue
height of 3 metres. The flue spigot restrictor must be removed when
installing into pre-cast flue applications. This appliance has been test
ed for use in a pre-cast flue block complying with BS 1289. In
accordance with BS 1289 Part 1, 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 HEARTH FITTING
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 top surface at least 50 mm above the floor level. The
hearth must be fitted symmetrically about the fire opening and have a
minimum width of 760 mm and a minimum projection of 300 mm
forwards from the fire opening.
1.10 WALL MOUNTING
The fire can be fitted to non-combustible walls. The top of the fire
place opening being at least 550mm above the floor level.
The wall should be plugged and the fire secured to the wall with suitable
screws. See” Wall Mounting” in the installation section.
1.11 SPILLAGE MONITORING 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 partial or complete blockage of the flue
causing a build up of combustion products in the room in which the fire
is operating. The following are important warnings relating to the
spillage monitoring system:
The spillage monitoring system must not be adjusted by the
Installer. The spillage monitoring system must not be put out of action.
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 the appliance, only a complete
pilot assembly (including thermocouple) may be fitted.
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2.1 PACKING CHECK LIST
1 off Firebox / Burner Assembly
1 off Flue Spigot
1 off Closure Plate
1 off Literature / Loose Items Pack
4 off Ceramic Radiants – Packed inside top fitting
2.2 INSTALLATION OF FIRE
2.2.1 Preparation.
a) Remove the dress guard by springing the location wires out at the top
and lifting away. See Fig. 2. Take care not to scratch the trim.
Fig. 2 Remove the Dress Guard.
b) Remove the flue spigot restrictor if the fire is to be fitted to a pre cast
flue. The flue spigot restrictor is attached to the spigot with two
screws.
c) Fit the flue spigot to the back panel using four screws provided.
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Closure plate.
a) Fit the closure plate to the fireplace opening and ensure that it has a flat
sealing area of at least 10mm sealed on all sides. See Fig. 3 below
Dimensions stated are for closure plate supplied
Check the operation of the chimney as follows:-
Apply a smoke match to the flue spigot opening in the closure plate and observe
the smoke. If there is a definite flow into the opening then proceed with the instal-
lation. If there is not a definite flow into the opening, pre-heat the chimney for
about two minutes and retest for flow. If there still is no definite flow into the open-
ing, the chimney may require attention. DO NOT FIT THE FIRE-SEEK EXPERT
ADVICE.
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Minimum 10mm
Flat Sealing Area
Spigot Opening
168 x 68mm
660mm
460mm
390mm to
CTR
525mm Minimum
650mm Maximum
Fireplace
Opening
Dimensions
Closure
Plate
Dimensions
305mm Minimum
440mm Maximum Air Relief Openings
Fig. 3

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2.3 GAS CONNECTION
Note : A means of isolation must be provided near to the appliance to facilitate
servicing.
Ensure that the gas supply is turned off before commencing.
The gas connection should be made to the appliance inlet elbow using 8 mm rigid
tubing. The gas connection can be made left hand, right hand or rear. In line with
current installation regulations, a restrictor should be fitted to the inlet pipework to
isolate the appliance for servicing and repair purposes.
Before making the final gas connection, thoroughly purge the gas supply
pipe work to remove all foreign matter, otherwise serious damage may be
caused to the gas control valve on the fire.
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2.4 GAS TIGHTNESS
a) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
b) Turn on the main gas supply and light the fire as described in section
3.2 and carry out a gas tightness test.
c) Check that the gas pressure is 20.0 mbar (± 1.0 mbar), 8.0 in w.g. +/-
0.4 in w.g.
d) 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.
3.1 Completing the Assembly
a) Fit the radiants by carefully inserting the upper end first into the radiant
canopy, and then lowering and seating the base of the radiants into the
radiant support channel.
b) Refit the dress guard.
3.2 Lighting the Appliance
a) Light the pilot by depressing the control knob at the “off” position and
turn anti-clockwise (with the control depressed) to the second position
marked *.
b) When the pilot lights, (pilot can be seen through the bottom window of
right hand radiant) hold the control knob down for 10 seconds.
c) If the pilot fails to light, repeat the ignition sequence and hold in the
control knob for slightly longer.
d) When the pilot has lit, release the control knob from the depress
position, depress slightly again and turn the control anti-clockwise to the
high position and check for clearance of combustion products as
detailed below.
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3.3 Checking for Clearance of Combustion Products
a) Close all doors and windows in the room. Remove the dress guard.
b) Light the fire and turn to the maximum position.
After 5 minutes hold the smoke match as shown in Fig. 4. Whilst hold
ing the smoke match in the correct position, approximately 5mm below
and inside the lower edge of the centre of the canopy.
Ensure that most of the smoke is drawn into the flue aperture. If in
doubt repeat the exercise after a further 5/10 minutes.
Note:- It is recommended that the smoke match is fitted into an approved
smoke match holder, when checking for clearance of combustion
products.
Fig. 4
e) If the smoke is not drawn into the flue aperture, remove the flue spigot
restrictor if fitted and repeat the spillage test.
If there is an extractor fan fitted in a joining room, then the spillage test must be
repeated with the fan switched on and running at maximum speed. All
interconnecting doors must be opened in accordance with the latest issue of BS
5440.
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Smoke match position
approx. 5mm below
and inside the front
edge of the combustion
chamber lid.

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IF SPILLAGE IS DETECTED
The cause must be discovered and the fault corrected. If the fault cannot be cor-
rected disconnect the appliance from the gas supply and seek expert advice.
Possible causes of spillage from the appliance are:- chimney restriction, down
draught or insufficient air supply to the room.
g) 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.
3.4 Final Check
a) Refit the Dress-guard if it has not already been re-fitted.
b) Recheck the operation of the fire on all settings.
c) Make sure that the User knows how to operate the fire and refer them
to the User Book.
d) Inform the User that the Model Number for ordering parts is shown on
the Rating plate. The rating plate can be viewed at the bottom left hand
side of the rear panel.
e) Inform the User the fire should be serviced annually for continued safe
operation.
f) Hand this instruction booklet to the customer.
3.5 Electrical Connection
The Flavel Welcome heater is supplied with a moulded three-pin plug (3 Amp) and
approximately 1.8 metres of flexible mains cable (1mm2). The appliance and
surround should therefore be located close to a suitable mains socket to enable
connection. The electrical socket MUST be easily accessible to allow
disconnection.
This heater MUST be earthed. If in any doubt consult a suitable competent person.
Connections
L = Brown N = BlueE = Green / Yellow
Replacement fuses should be approved and conform to BS 1362.
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MAINTENANCE INSTRUCTIONS
Servicing Notes
Servicing should be carried out annually by a competent person such as a
Corgi registered engineer. The service should include visually checking the
chimney and fire opening for accumulations of debris and a smoke test to
check for positive up-draught in the chimney. The condition of the ceramic
plaques 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.
Ensure before any servicing work is commenced that the applinace is
isolated from the electrical supply.
4.1 GENERAL ACCESS FOR SERVICING
4.1.1 TO REMOVE THE UPPER CANOPY
a) Prepare work area (lay down dustsheets etc.), Disconnect the appliance
from the gas supply.
b) Remove the four canopy rear fixing screws, and the two fixing screws
that are located on the underside of the canopy (see fig 5 & 6
respectively)
c) Remove the radiants and move to a safe place
d) Re-assemble in the reverse order.
Fig. 5 Removing the four canopy rear fixing screws
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Fixing Screws

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Fig. 6 Removing the Upper Outer Case Fixing Screws
4.2 REMOVING THE BURNER ASSEMBLY FROM THE FIRE
a) Disconnect the appliance from the gas supply.
Fig. 7
b) Remove the coal form from the front of the appliance, as shown above
in Fig. 7
c) Remove the front bezel by unscrewing the 2 retaining screws, as shown
in Fig. 8 overpage.
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Fixing Screws

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Fig. 8
d) Remove the four burner retaining screws, as shown below in fig. 9.
Disconnect the pilot assy. and slide the burner carrier to the right and lift
clear.
Fig. 9
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Front bezel retaining
screws
Burner
Fixing
Screws

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4.3 REMOVING THE GAS VALVE FROM THE FIRE
a) Disconnect the appliance from the gas supply.
b) Remove the upper canopy as shown in section 4.1
c) Remove the left hand side panel, by unscrewing the rear panel fixing
screws, then the base panel retaining screw, as shown below in fig. 10
Fig. 10
c) Disconnect the pipes to the control valve and the control valve locknut
as shown below in Fig. 11
Fig.11
Rear side panel
retaining screws
Front retaining
screw on the
underside of
the leg support
bracket
Gas Inlet Pipe
Main Supply Pipe
Pilot Pipe
Control Valve
Locknut
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d) Remove the thermocouple, which is a push fit into the rear of the control
valve.
4.4 REMOVING THE ODS- PILOT ASSEMBLY
Note : Because this appliance is fitted with an atmosphere sensing ODS-pilot
it is not possible to replace the thermocouple separately, because the
thermocouple position is factory set to a tight tolerance. Any replacement of
parts on the pilot requires a complete new pilot assembly.
a) Remove the front panel and front bezel as described in section 4.2
b) Unscrew the pilot fixing screws. These can be accessed from the front
of the appliance with the front panel and bezel removed.
c) Remove the thermocouple as described in section 4.3. (d)
4.5 REMOVAL / REPLACEMENT OF THE RADIANTS
Remove the radiants by lifting them slightly then pulling forward as shown
in Fig. 12 below.
Fig. 12
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4.6 REMOVAL / REPLACEMENT OF THE LIGHTBULBS
a) Isolate the appliance from the electricity supply.
b) Remove the coal form as shown on page 16, Fig 7.
c) Remove the bulbs from the bayonet fitting and replace with a new one
of the correct specification, as shown below in Fig. 13
Fig. 13
PARTS SHORTLIST
Replacement of any other parts must be carried out by a competent person such
as a CORGI registered gas installer or competent electrician.
The part numbers of the user replaceable parts are as follows, these are available
from specialist spares stockists whose details can be found on our web site,
www.cfm-europe.com, in the ‘stockist’ section.
Ceramic Plaques Set FC-P079648
Gas valve B-63250
ODS Pilot Assy. (NG) B-48360
Control Knob B-63520
Injector B-63240
Mains Cable B-77270
Due to our policy of continual improvement and development the exact
accuracy of illustrations and descriptions contained in this book cannot be
guaranteed.
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Bayonet Fitting