Flavel Ora User manual

Ora
Aluma
Toccata
COAL EFFECT GAS FIRE
Installation and Maintenance Instructions
Hand these instructions to the user
Model No’s FSRNAEG, FSRNAAG, FSRNOEG, FSRNOAG, FNRN42G,
FSTN11G, FSTN12G & FSTN23G are for use on Natural Gas (G20) at a
supply pressure of 20 mbar in G.B. / I.E.

CONTENTS
Section 1 Information and Requirements PAGE
1.0 Appliance Information 3
1.1 Conditions of Installation 4
1.2 Flue and chimney suitability 4
1.3 Fireplace / surround suitability 5
1.4 Shelf position 5
1.5 Chimney inspection 5-6
1.6 Fire place opening / catchment space 6
1.7 Fitting to Chair bricks 8
1.8 Precast Flues 8
1.9 Metal Flue boxes 8
1.10 Hearths 9
1.11 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 soundness and burner pressure 17
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 18-21
3.2 Fitting the trim (Ora / Aluma models) 22
3.3 Fitting the trim (Toccata models) 22
3.3 Fitting the fender (all models) 22-23
3.5 Lighting the appliance 23
3.6 Checking for clearance of combustion
products 24
Section 4 Maintenance
4.1 Removal of the Burner Assembly 25
4.2 Removal of the Battery Ignitor 26
4.3 Repacing the Battery 26
4.4 Removing the Oxy-Pilot Assembly 26
4.5 Replacing the Control Cable 27-28
This appliance is manufactured by:-
CFM Europe Ltd,
Trentham Lakes,
Stoke-on-Trent,
ST4 4TJ
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APPLIANCE INFORMATION
Model FSRN**G FSTN**G
** denotes trim & fret variant
Gas Type G20
Main injector (1 off) Size 480
Pilot Type S.I.T. Oxystop YA OP 9022
Max. Gross Heat Input : 6.5 kW
Min. Gross Heat Input : 4.2 kW
Cold Pressure : 20.0 +/-1.0 mbar (G20)
Ignition : Piezo Ignitor (all models)
Electrode Spark Gap 4.0mm
Weight (without fender) 17.0 kg (all models)
Fire box Dimensions (with trim fitted Ora / Aluma models)
Width : (with standard trim, no spacer) 500mm
Height : (with standard trim, no spacer) 610mm
Depth : (overall-with fender) 140mm
Depth : Flush-fit (from mounting face to rear) 105mm
Gas Connection 8mm Compression (Supplied with fire)
Fire box Dimensions (with trim fitted Toccata models)
Width : (with standard trim, no spacer) 490mm
Height : (with standard trim, no spacer) 610mm
Depth : (overall-with fender) 140mm
Depth : Flush-fit (from mounting face to rear) 105mm
3

INSTALLATION REQUIREMENTS
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
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. 1289 Clay Flue Blocks and Terminals
8. I.S. 813 : 1996 Domestic Gas Installation (Republic of Ireland)
In Republic of Ireland :-
No 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 National
Standards Authority of Ireland. If installing in Northern Ireland, please
consult local building regulations. Any purpose made ventilation must be
checked periodically to ensure that it is free from obstruction.
1.2 FLUE AND CHIMNEY 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 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 (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.
4

1.3 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.
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 FLUE / 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. 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 chim
ney / 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 OPENING AND CHIMNEY CATCHMENT SPACE
The front opening of the fire place must be between 330 and 430 mm wide, and
between 550 and 565mm 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
330mm Minimum
430mm Maximum
610mm
Minimum
520mm Minimum
Fig. 1
550mm Minimum
565mm Maximum
Minimum Flat
Sealing Area
6

Table A - Installation Depth Requirements for a Flavel Ora / Aluma / Toccata
being installed into a brick built chimney, requiring 12.0 litres of debris
collection volume (fig. 2)
330 (minimum opening width) 183
340 178
350 173
360 170
370 167
380 163
390 158
400 155
410 151
420 146
430 (maximum opening width) 143
For example, if the appliance was to be fitted into a 400mm wide opening, the
depth required would be 189mm. See fig. 2 below for explanatory diagram.
Fig. 2
7
Opening Width ( e.g. 400mm)
Depth Required
(e.g. 155mm)

1.7 FITTING TO FIREPLACES WITH EXISTING CHAIRBRICKS AND
CONVENTIONAL BRICKBUILT CHIMNEYS
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 190mm. If the depth is less than 190mm 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 collec-
tion 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.
1.8 FITTING TO PRE-CAST FLUE INSTALLATIONS
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
120mm 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 120 mm to the rear of
the starter block, otherwise there will be insufficient depth. To increase this depth
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 CFM Europe for advice before proceeding.
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 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 FITTING TO PRE-FABRICATED TWIN WALL METAL FLUE BOXES
The appliance may be fitted to twin wall metal flue boxes conforming to the con-
structional 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 maxi-
mum 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

1.10 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.
1.11 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 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

SECTION 2
INSTALLATION OF FIRE
2.1 UNPACKING THE FIRE
Carefully lift the fire out of the carton. Remove the loose item packaging carefully
from the front of the appliance. Check the contents as listed :-
Packing Check List
1 off Fire box / burner assembly
1 off Boxed ceramic base, front ceramic rail and fire bed and 22 synthetic
coals (2 small, 20 large), 1 off fuelbed insulation mat.
1 off each User instruction book and Installation book
1 off Trim (attached to appliance on Ora / Aluma models, packed on Toccata)
1 off Flue restrictor baffle (for use in brick built chimneys and large diameter
e.g. 175mm flue applications).
Fixing Kit Check List
2 off Fixing cables
4 off Wallplugs
4 off Eyebolts
2 off Tensioner bolts & nuts
2 off Tensioner screws
2 off Fender fixing screws
2 off Fender fixing brackets (L/H & R/H)
Fender Box
1 off Fender & Ashpan Cover
2.2 INSTALLING 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, or insulated pre-fabricated
metal flue box to B.S. 715.
When installing into 125mm (5 inch) diameter lined brick or stone flue, or
insulated pre-fabricated metal flue box to B.S. 715 and pre-cast flues the
restrictor baffle must not be fitted.
Aspillage 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

a) Remove the trim (Ora / Aluma models only). 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

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 sup-
port 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. 5 & 6 below for
suggested concealed pipe layouts.
Fig. 5
Fig. 6
Note : 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.
There is a choice of methods of fixing the firebox which are provided to enable the
installer to deal with any type of installation.
12
Firebox
Fireplace
Builders
Opening
Gas Supply
Firebox
Approx.
40mm Fireplace
Gas Supply
Approx.
40mm

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-
e) Mark out and drill 4 off No 14 (6mm) 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.
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 overpage
20mm
500mm Fireplace Opening
100mm
250mm
13

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 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.
14

m) Refit the front burner heat shield to the sides of the fire box (2 Screws)
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
15
430mm
300mm
133mm
Firebox
Mounting
Flange
420mm

2.3 GAS SOUNDNESS AND INLET PRESSURE
a) Remove the pressure test point screw from the inlet elbow pressure test
point and fit a manometer.
b) Turn on the main gas supply and carry out a gas soundness test.
c) Depress the control lever to the position marked pilot. Hold down the
control lever for a few seconds to purge the pipe work. The burner
should light, continue to hold the control lever for a few seconds to latch
the slide valve then lift 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.) for FSRN**G & FSTN**G models
e) Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas soundness with the
appliance turned on using a suitable leak detection fluid or detector.
16

3.1 ASSEMBLING THE CERAMICS AND FUEL BED
a) Place the insulation mat centrally on to the fuelbed support then place
the ribbed hard ceramic fuelbed base on top of the mat and pull both
fully forwards to the burner. Make sure that the fuelbed base is
located centrally in the fire box. Ensure that both the mat and
fuelbed base fit fully down onto the fuel bed support and are not
lodged on the burner. See fig. 10 below.
Fig. 10
b) Position upper fuelbed component on to the locating pegs on the top of
the fuelbed base, ensuring that it is correctly seated as shown below in
fig. 11
Fig. 11
17

c) Fit the two parts of the ceramic front coal support on to the front support
bracket, ensuring they are correctly located over the locating tabs, as
shown below in fig. 12
Fig. 12
d) Select seven of the coals and arrange along the front ceramic coal
support using the shallow depressions as guidance for the
coal position. See fig. 13 below
Fig. 13
18

e) Select the four coals and arrange along the front of the fuelbed, direct
ly behind the front row of coals. Leave gaps between the
coals in line with the front flame notches on the front of the fuelbed
(shown below arrowed), this enhances the front flames and provides the
most pleasing flame effect. Select the two smallest coals and place
them at each end of the second row of coals. See fig. 14 below.
Fig. 14
f) Select five of the coals and arrange along the fuelbed behind the
second row of coals spacing them evenly and positioning them as
shown below in fig. 15
Fig. 15
19

g) Select the remaining four coals and position to fill the gaps left at the
top rear of the fuelbed. The coals will locate naturally into the
depressions in the top rear of the fuelbed, see fig 16 below
Fig. 16
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 polythene 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