Flavel Linear Mounting instructions

enilworth & Linear
DECORATIVE FUE -EFFECT GAS FIRES
THIS PRODUCT IS NOT SUITAB E FOR
PRIMARY HEATING PURPOSES
Installation, Maintenance & User Instructions.
Hand these instructions to the user after installation.
Model No’s FRDC**MN, FRDP**MN & FRDC**RN2 are for use on
Natural Gas (G20) at a supply pressure of 20 mbar in G.B. / I.E.
** denotes variant of trim / fascia where applicable

CONTENTS PAGE
Section 1 Information and Requirements PAGE
1.0 Appliance Information 3-4
1.1 Conditions of Installation 5
1.2 Flue and chimney suitability 5
1.3 Fireplace / surround suitability 6
1.4 Shelf position 6
1.5 Chimney inspection 6-7
1.6 Fire place opening / catchment space 7-8
1.7 Fitting to metal flue boxes 8
1.8 Hearths 9
1.9 Pre-cast flue installations 9
1.10 Spillage monitoring system 9
Section 2 Installation of Fire
2.1 Unpacking the fire 10
2.2 Installing the fire box 10-15
2.3 Gas tightness and inlet pressure (manual control models) 16
2.4 Gas tightness and inlet pressure (remote control models) 16
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed (coal variants) 17-20
3.2 Assembling the ceramics and fuel bed (pebble variants) 21-23
3.3 Lighting the appliance (manual control models) 24
3.4 Fitting the batteries (remote control models) 25-26
3.5 Manually lighting remote control models 26
3.6 Lighting the appliance (remote control models) 27-28
3.7 Fitting the trim or fascia 29
3.8 Fitting the fender 29
3.9 Checking for clearance of combustion products 29
Section 4 Maintenance
4.1 Removal of the burner assembly (manual control models) 30
4.2 Removal of the piezo igniter (manual control models) 30
4.3 Removal of the control tap (manual control models) 31
4.4 Removal of the pilot assembly (manual control models) 31
4.5 Removal of the burner assembly (remote control models) 32
4.6 Removal of the valve (remote control models) 32
4.7 Removal of the oxy-pilot assembly (remote control models) 32-33
4.8 Replacing the batteries (remote control models) 33
Part shortlist 34
Section 5 User Instruction Section
5.1 Conditions of Installation & about your new fire 35-36
5.2 Operating the fire (manual control models) 37
5.3 Operating the fire (remote control models) 38-39
5.4 Manually operation of remote models 40-41
5.5 Replacing the batteries in remote control models 41
5.6 Spillage monitoring system 42
5.7 Cleaning instructions 42
5.8 Re-assembling the ceramics and fuel bed (coal variants) 43-46
5.9 Re-assembling the ceramics and fuel bed (pebble variants) 47-49
User replaceable parts 50
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APP IANCE INFORMATION
Model FRDC**MN (MC) FRDC**RN2 (RC)
FRDP**MN (MC)
Gas Type G20 G20
Main injectors (2 off) Size 260 Size 280
Pilot Type Copreci ERTA OXYP
21100 / 141 (MC) PG-83-10 (RC)
Max. Gross Heat Input : 6.9 kW
Min. Gross Heat Input : 4.2 kW
Cold Pressure : 20.0 mbar +/- 1.0mbar
Ignition : Push Button Piezo (MC models)
4.5V Battery Generator (RC models)
Electrode Spark Gap 4.5mm Nominal
Weight 14kg
This appliance is manufactured by:-
BFM Europe Ltd,
Trentham Lakes,
Stoke-on-Trent,
ST4 4TJ.
3

Fire box Dimensions
Width : (with trim, no spacer) 498mm
Height : (with trim, no spacer) 600mm
Depth : (overall-without fender) 170mm
Gas Connection 8mm Compression (Supplied with fire)
Appliance Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2009 + A1 : 2013 and the result is 41%.
The gross calorific value of the fuel has been used for this efficiency
calculation.
The test data from which it has been calculated has been certified by BSI.
The efficiency value may be used in the UK Government’s Standard
Assessment Procedure (SAP) for energy rating of dwellings.
4

INSTA ATION REQUIREMENTS
1.1 CONDITIONS OF INSTA ATION
It is the law that all gas appliances are installed only by a GAS SAFE Registered
Installer, in accordance with these installation instructions and the Gas Safety
(Installation and Use) Regulations 1998 as amended. Failure to install appliances
correctly could lead to prosecution. It is in your own interest and that of safety to
comply with the law.
The installation must also be in accordance with all relevant parts of the Local and
National Building Regulations where appropriate, the Building Regulations
(Scotland Consolidation) issued by the Scottish Development Department, and all
applicable requirements of the following codes of practice :-
1. BS 5871 Part 2 Installation of Inset Live Fuel Effect Gas Fires
2. BS 6891 Installation of Gas Pipework
3. BS 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. BS 1251 Open fire place components
5. BS 715 / BS EN 1856-2 Metal flue pipes for gas appliances
6. BS 6461 Part 1 Installation of Chimneys and flues
7. IS 813 : 1996 Domestic Gas Installation (Republic of Ireland)
No purpose made additional ventilation is normally required for this
appliance, when installed in G.B. When Installing in I.E. please consult
document I.S. 813 : 1996 Domestic Gas Installation, which is issued by the
National Standards Authority of Ireland. If installing in Northern Ireland,
please consult local building regulations. Any purpose made ventilation
must be checked periodically to ensure that it is free from obstruction.
1.2 F UE AND CHIMNEY SUITABI ITY
This appliance is designed for use with conventional brick built or lined chimneys
and fabricated flues and metal flue boxes conforming to BS 715 / BS EN 1856-2.
All flues must conform to the following minimum dimensions.
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
fit the flue restrictor baffle (supplied) to reduce the flue flow and increase the
efficiency of the fire. Safe clearance of products must always be checked by
carrying out a smoke match test as described.
5

1.3 FIREP ACE / SURROUND SUITABI ITY
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
proprietary fire place surrounds with a temperature rating of at least 150oc.
If a heating appliance is fitted directly against a wall without the use of a fire
surround or fire place all combustible material must be removed from behind
the trim. Soft wall coverings such as blown vinyl, wall paper etc. could be
affected by the rising hot air and scorching and/or discoloration may result.
Due consideration should be made to this when installing or decorating.
1.4 SHE F 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 F UE / CHIMNEY 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.
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.
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.
6

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 P ACE OPENING AND CHIMNEY CATCHMENT SPACE
The front opening of the fire place must be between 370 and 440mm 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 figure 1.
When installing into a brick built chimney, you must ensure that there is sufficient
depth to accomodate any debris which may fall from the chimney. This depth
must be sufficient to accomodate 12 litres of volumetric space.
Fire Opening
370mm Minimum
440mm Maximum
580mm
Minimum
460mm Minimum
Fig. 1
550mm Minimum
570mm Maximum
Minimum Flat
Sealing Area
7

Table A - Installation Depth Re uirements for a Flavel Kenilworth or Linear,
being installed into a brick built chimney, re uiring 12.0 litres of debris
collection volume (figure 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 (not suitable for
use with Linear models). This spacer frame can be purchased from Flavel Fires
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 370mm wide opening (without
a chairbrick), the depth required would be 170mm. See figure 2 below for
explanatory diagram.
Fig. 2
1.7 FITTING TO PRE-FABRICATED TWIN WA META F UE BOXES
The appliance may be fitted to twin wall metal flue boxes conforming to the
constructional requirements of BS 715 / BS EN 1856-2, (for example the Selkirk
LFE 175 box). The box must have a minimum flue diameter of 125mm internal
and minimum internal dimensions of 300mm deep by 580mm high by 400mm
wide. There are no maximum dimensional requirements for the box. The top face
of the box must be insulated with a minimum thickness of 50mm of
non-combustible mineral wool insulation or similar material. The flue box must
stand on a non-combustible base of minimum thickness 12mm.
8
Opening Width ( e.g. 370mm)
Depth Required
(e.g. 170mm
minimum)

1.8 HEARTHS
This appliance must only be installed on to a concrete or non-combustible hearth.
The hearth material must be a minimum thickness of 13mm 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.
1.9 FITTING TO PRE-CAST F UE INSTA ATIONS
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 (only suitable for, 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 EN
1858. In accordance with BS EN 1858, pre-cast flues built with directly plastered faces
(front or rear) are not correctly installed as to ensure proper operation with any type of
gas fire. In some instances of this flue construction, temperature cracking of surface
plaster may occur through no fault of the appliance. An air gap or some form of
insulation material should be installed to prevent normal flue temperatures from
damaging wall surfaces.
1.10 SPI AGE 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 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
INSTA ATION OF FIRE
2.1 UNPACKING THE FIRE
Carefully lift the fire out of the carton. Remove the loose item packaging carefully
from the front of the appliance. Check the contents as listed :-
Packing Check List
1 off Fire box / burner assembly
1 off Boxed ceramic base, front ceramic rail and 18 coals (16 large, 2 small) -
enilworth models only
or
1 off Boxed ceramic base, front ceramic rail and 18 pebbles (16 large, 2
small) - Linear model only
1 off Loose items bag, which includes (where applicable) :-
1 off Remote control handset (RC models only)
1 off Restrictor baffle (all models)
1 off Cable fixing kit (all models)
1 off Length of foil tape (all models)
1 off Installation / user instruction book (all models)
5 off 1.5V batteries (RC models only, 3 off for control valve, 2 off for handset)
1 off Guarantee card (all models)
2.2 INSTA ING THE FIRE BOX
Establish which type of flue you are intending to install the fire in to :-
225 x 225mm (9 inch x 9 inch) brick built chimneys 175mm (7 inch) diameter lined brick or stone
flue, insulated pre-fabricated metal flue box to BS 715 / BS EN 1856-2 or Pre-Cast Flue to BS EN
1858
When installing into 125mm (5 inch) diameter lined brick or stone flue, or insulated pre-fabricated
metal flue box to BS 715 / BS EN 1856-2. 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

For manual control models proceed as follows :-
2.2.1 Remove the burner heat shield from the front of the fire box to allow
access to the burner. See figure 3 below.
Fig. 3
2.2.2 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.
2.2.3 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 figure 4 below.
Fig. 4
11

For remote control models proceed as follows:
2.2.4 Remove the trim. Remove the burner heat shield from the
front of the fire box to allow access to the burner. See figure 5 below.
Fig. 5
2.2.5 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.
2.2.6 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 figure 6 below.
Fig. 6
12

Continue for all models
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 of the fire box below the fuelbed
support panel and connect to the isolating / inlet elbow. The gas connection to the
appliance should be made to the isolating / inlet elbow using 8mm rigid tubing.
There must be no soldered joints within the firebox. See figure 7 & 8 below for
suggested concealed pipe layouts.
Fig. 7
Fig. 8
Note : Before breaking into the gas supply a tightness 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.
In line with current GAS SAFE 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.
13
Firebox
Fireplace
Builders
Opening
Gas Supply
Firebox
Approx.
40mm Fireplace
Gas Supply
Approx.
40mm
Builders
Opening

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.
To fit using the preferred cable method proceed as follows-
2.2.7 Mark out and drill 4 off No 14 (6mm) holes in the back face of the fire
opening in the positions shown below in figure 9.
Fig. 9
Fit the wallplugs provided and screw the fixing eyes securely into the rear of the
fire opening.
2.2.8 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.
2.2.9 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.
2.2.10 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).
2.2.11 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 figure 10 overpage.
14
20mm
500mm Fireplace Opening
100mm
250mm

Fig. 10
2.2.12 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.
2.2.13 With the fire securely in place, if a concealed gas connection has been
made through either of the access holes in the sides of the fire, the
holes should be closed around the pipe to prevent leakage of air
through the gap around the pipe.
2.2.14 Refit the burner. Fit the four retaining screws and check that the burner
is correctly locked into position.
2.2.15 Refit the front burner heat shield to the sides of the fire box (2 screws)
2.2.16 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.
15

2.3 GAS TIGHTNESS AND IN ET PRESSURE - MANUA CONTRO
MODE S.
2.3.1 Remove the pressure test point screw from the inlet elbow and fit a
manometer.
2.3.2 Turn on the main gas supply and carry out a gas tightness test.
2.3.3 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.
2.3.4 Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.)
2.3.5 Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.
2.4 GAS TIGHTNESS AND IN ET PRESSURE - REMOTE CONTRO
MODE S
2.4.1 Remove the pressure test point screw from the inlet elbow and fit a
manometer.
2.4.2 Turn on the main gas supply and carry out a gas tightness test.
2.4.3 Light the fire, see page 25 to 28 for full details of the operating method
for the fire.
2.4.4 Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.)
2.4.5 Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.
16

SECTION 3
ASSEMB ING FUE BED AND COMMISSIONING
3.1 ASSEMB ING THE CERAMICS AND FUE BED - COA MODE S
3.1.1 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 figure 11 below.
Fig. 11
3.1.2 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 figure 12 below)
Fig. 12
17

3.1.3 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 figure 13 below)
Fig. 13
3.1.4 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 figure 14 below)
Fig. 14
18

3.1.5 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 figure 15 below)
Fig. 15
3.1.6 Select two small coals and position to fill the gaps at each end of the
third row of coals, as shown. (See figure 16 below).
Fig. 16
19

3.1.7 Select the remaining four large coals and position on the rear of the
fuel-bed matrix. (See figure 17 below).
Fig. 17
The exact position and fit of the coals may be finely adjusted to give the most
pleasing and random appearance.
Warning : Use only the coals supplied with the fire. When replacing the
coals remove the old coals and discard them. Fit a complete set of
coals of the correct type. Do not fit additional coals or any coals
other than a genuine replacement set.
This appliance uses fuel effect pieces containing Refractory Ceramic Fibres (R.C.F.), which are
man-made vitreous silicate fibres. Excessive exposure to these materials may cause temporary
irritation to eyes, skin and respiratory tract. Consequently, it makes sense to take care when
handling these articles to ensure that the release of dust is kept to a minimum. To ensure that the
release of fibres from these R.C.F. articles is kept to a minimum, during installation & servicing we
recommend that you use a HEPA filtered vacuum to remove any dust and soot accumulated in and
around the fire, before and after working on the fire. When replacing these articles we
recommend that the replaced items are not broken up, but are sealed within a heavy duty poly-
thene bag, clearly labelled as “RCF waste”. This is not classified as “hazardous waste” and may
be disposed of at a tipping site licensed for the disposal of industrial waste. Protective clothing is
not required when handling these arrticles, but we do 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. This appliance does not contain any component manufactured from asbestos
or asbestos related products.
20