Flavel Orchestra User manual

Orchestra
COA EFFECT BA ANCED F UE GAS FIRE
Installation and Maintenance Instructions
Hand these instructions to the user
Model No’s FBFN76G & FBFN98G are for use on Natural Gas (G20) at a
supply pressure of 20 mbar in G.B. / I.E.
Model No’s FBFP76G & FBFP98G are for use on Propane Gas (G31) at a
supply pressure of 37 mbar in G.B. / I.E.

CONTENTS
PAGE
Section 1 Information and Requirements
1.0 Appliance Information 3
1.1 Conditions of Installation 4
1.2 Fireplace surround & suitability 4
1.3 Flue Terminal Position 5
1.4 Shelf position 6
1.5 Hearths 6
Section 2 Installation of Fire
2.1 Unpacking the fire 6
2.2 Fireplace opening 6-7
2.3 Preparation of the wall 8
2.4 Preparation of the flue hole 9
2.5 Preparation of the flue pipes 10
2.6 Installation of the gas supply 11-12
2.7 Securing of the firebox to the wall 12-14
2.8 Preparation for mounting the flue terminal 15
2.9 Fitting the terminal guard 16
2.10 Removal & refitting of the glass frame 16
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the fuel bed 17-18
3.2 ighting the appliance 19
3.3 Fitting the Fret 19
Section 4 Maintenance
4.1 Removal of the Burner Assembly 19
4.2 Removal of the Piezo Igniter 20-21
4.3 Removal of the Control Valve 21
4.4 Removal of the Pilot Assembly 21-22
The model no. of this appliance is affixed to the control panel and it is
manufactured by:-
BFM Europe td, Trentham akes, Stoke-on-Trent, Staffordshire, ST4 4TJ
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APP IANCE INFORMATION
Main injector : (1 off) Stereomatic Injector Elbow – size 60 (NG)
size 19 ( PG)
Pilot Type : S.I.T.140 Series NG – size 27
PG - size 19
Max. Gross Heat Input : 3.8 kW
Min. Gross Heat Input : 2.5 kW
Gas Rate : 0.345 m3/hr – NG models
0.139 m3/hr – PG models
Cold Pressure : 20.0+/-1.0 mbar (8.0 +/- 0.4 in w.g.)
37.0+/-1.0 mbar (14.8 +/- 0.4 in w.g.)
Ignition : Push-button Piezo
Electrode Spark Gap : 4.0mm
Weight (with fender) : 30.0 kg inclusive of flue pipe and terminal
Fig 1
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS EN 613 : 2001 and the result is 74%.
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 UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings.
3
470mm
580mm
50mm
435mm
150mm

INSTA ATION REQUIREMENTS
1.1 CONDITIONS OF INSTA ATION
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 ocal 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. 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 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 propri-
etary fire place surrounds with a temperature rating of at least 150oc.
If a heating appliance is fitted directly against a wall without the use of a fire
surround or fire place all combustible material must be removed from behind
the trim. Soft wall coverings such as blown vinyl, wall paper etc. could be
affected by the rising hot air and scorching and/or discoloration may result.
Due consideration should be made to this when installing or decorating.
4

1.3 F UE TERMINA POSITION
The minimum acceptable dimensions from the flue terminal to obstructions
and ventilation openings are shown below and listed in the table
It is important that the position of the flue allows the free passage of air
across it at all times. The minimum acceptable space from the flue terminal
to obstructions and ventilation openings are specified below (Fig. 2)
Fig. 2
DIMENSION TERMINA POSITION MINIMUM DIMENSION
A Directly below an opening, air brick, 300mm (12in)
opening window
B Above an opening, air brick, 300mm (12in)
opening window
C Horizontally to an opening, air brick,
opening window etc.
D Below gutters, soil pipes or drain pipes 300mm (12in)
E Below eaves 300mm (12in)
F Below balconies or car port roof 600mm (12in)
G From a vertical drain pipe or soil pipe 300mm (12in)
H From an internal or external corner 600mm (24in)
I Above ground roof or balcony level 300mm (12in)
J From a surface facing the terminal 600mm (24in)
K From a terminal facing the terminal 600mm (24in)
From an opening in the car port 1200m (48in)
M Vertically from a terminal on the same wall 1500mm(59in)
N Horizontally from a terminal on the 300mm (12in)
same Wall
O NOT APP ICAB E N/A
P NOT APP ICAB E N/A
Q NOT APP ICAB E N/A
5

1.4 SHE F POSITION
The fire may be fitted below a combustible shelf providing there is a minimum dis-
tance of 200mm above the top of the fire and the shelf does not project more than
150mm. If the shelf overhangs more than 150mm the distance between the fire
and the shelf must be increased by 15mm for every 25mm of additional overhang
over 150mm.
1.5 HEARTHS
This appliance does not require the fitting of a hearth, but we do recommend that
a hearth of minimum width 760mm and minimum projection forwards of 125mm is
used. This recommended hearth can be manufactured from combustible or non-
combustible material.
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 the pack. Check the contents as listed :-
IMPORTANT : THE CARDBOARD FITMENT THAT IS AT THE TOP OF THE
CONVECTION APERTURE SHOU D NOT BE REMOVED
UNTI THE APP IANCE IS FU Y INSTA ED AND READY
TO BE IT.
DO NOT UNDER ANY CIRCUMSTANCES USE THIS APP IANCE IF THE
G ASS PANE IS BROKEN OR NOT SECURE Y FIXED TO THE FIREBOX.
Packing Check ist
1off Fire box & foam seal / burner assembly
1off Trim & magnets
1off Fret, Ashpan & Mounting Brackets / Screws (Boxed)
1off Boxed ceramic one piece fuel bed
1off Flue Terminal unit
1off oose Items pack – containing:- Cable fixing kit, Section of Foil Tape
10 off rawplugs, 12 off No.8 x 10mm
screws
1 off 6mm Allen Key
1 off Right Hand Supply Pipe
10 off No.12 x 40mm fixing screws
1 off heat deflector
6

2.2 FIRE P ACE OPENING
The front opening of the fire place must be between 410 and 420mm wide, and
between 550 and 560mm high. If the opening exceeds these dimensions then a
surround must be constructed from suitable non-combustible material to produce a
suitable sized opening. Any surround must be suitably sealed to the fire place to
prevent leakage. See fig. 3 below
Fig.3
A min / max sized opening with a flat rear face between the fire opening and flue
outlet terminal is shown below. (fig 4).
Fig.4
7
575mm minimum
455mm minimum
Fire Opening
410mm minimum
420mm maximum
555mm
minimum,
565mm
maximum
Minimum Flat
Sealing Area
Minimum Cavity Depth
150mm. Maximum Flue
Length 600mm, dependent
on rebate available
Firebox Front
Outer Wall
Flue Outlet

NOTE : WHEN MEASURING ENGTH BETWEEN FIREBOX AND THE OUTER
WA TAKE INTO ACCOUNT THE DISTANCE BETWEEN THE BACK OF THE
FIREBOX AND THE INNER WA AS THIS WI VARY BETWEEN INSTA A-
TIONS, DEPENDENT UPON THE REBATE AVAI AB E. (DIMENSION “X”
BE OW - FIG. 5).
Fig. 5
The appliance must be fitted into a fireplace or false chimney constructed of non-
combustible materials, minimum width 402mm, minimum rebate 50mm (with
optional black 3” spacer fitted), or 125mm without black spacer fitted.
2.3 PREPARATION OF THE WA
The appliance and flue pipes must be installed at right angles to the mounting
wall. The appliance itself should be installed vertically against a flat wall. Where
an uneven wall surface is found, appropriate action should be taken to ensure that
the appliance is not stressed or does not distort when installed.
Ensure that the floor surface onto which the appliance is mounted onto is flat.
The minimum height from the floor to the centre of the flue is shown on fig. 6 over-
page.
760mm
402mm 125mm
X
Outer Wall
Inner Wall
472mm Including
Firebox Flanges
8

Fig. 6
2.4 PREPARATION OF THE F UE HO E
a) Mark the position of the centre of the flue on the inner wall.
b) Cut hole for outer flue pipe. There are two possible methods to achieve
this, either core drill or via hammer and chisel.
c) To core drill, proceed as follows :-
Drill a pilot hole through the wall, in position as specified in figure 5.
Using a 6” core drill, drill the flue hole.
To Hammer and chisel, proceed as follows :-
Mark the position of the centre of the flue pipe as specified in figure 5.
Mark the position of the hole around this point.
Chisel out the area as marked on the wall.
We then recommend that a cardboard cylinder is placed around the flue pipe and
inserted in the chiselled out hole whilst making good.
NOTE :- If the appliance is to be installed into a building under construc-
tion, it is recommended that a non-corrosive metal tube of 6” diameter be
inserted into the position of the hole as specified on page 5.
152mm Diameter
455mm
9

2.5 PREPARATION OF THE F UE PIPES
a) Place the firebox into the fire opening with the spacer (if required) fitted
and the fire surround correctly secured in the final position. From the
outside of the house measure from the face of the outside wall to the
rear panel of the firebox through the flue hole. This dimension is shown
below as dimension A, and cut the outer flue pipe (143mm diameter) to
Dimension “A”
Fig. 7
b) For the inner flue pipe, (87.5mm diameter) add an additional 25mm to
dimension “A” and cut the inner flue pipe squarely to length.
IMPORTANT : DO NOT CUT F ANGED ENDS OF F UE PIPE & ENSURE THE
PIPES ARE CUT SQUARE Y.
c) Using the screws and gaskets provided, fit both inner and outer flue
pipes to the firebox. (See Fig. 8 overpage).
d) Using mortar or sealing compound, seal the outer flue pipe to the out
side surface of the wall, (See Fig. 7 for position of mortar).
Flue erminal
Seal Area as indicated with
Mortar or Sealing
Compound
Wall hickness “ ”
Outer Cavity Wall
Inner Cavity Wall
Dimension ʻ“A”
Inner Flue
Pipe
Outer Flue
Pipe
10

Fig. 8
2.6 INSTA ATION OF THE GAS SUPP Y
Before installing the firebox, decide from which side or if a rear connection to the
gas supply is required. For R/H entry a purpose shaped gas supply pipe is
supplied.
Plan the pipe run to enter the firebox from the left, right or rear and connect to the
inlet elbow. See below :-
a) 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 and connect to
the inlet elbow. See fig. 9 overpage for a suggested concealed pipe
layout.
NO E : 12 off No. 8 x 10mm
Screws are provided, six off to
affix the inner flue pipe and six off
to affix the outer flue pipe
11

Fig 9. (without optional 3” black spacer).
Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound. Always block
the unused entry points into the firebox with the section of foil tape as
supplied.
2.7 SECURING OF FIREBOX TO THE WA
Dependent upon if the standard firebox fixing flange or if the appliance is fitted
with the black 3” spacer option, there is a choice of methods of fixing the firebox
that are provided to enable the installer to deal with any type of installation. The
preferred method of fixing the appliance is the cable fixing method, which is
described in detail in the following section.
If the standard firebox fixing flange is to be used, the firebox may be secured using
the cable method, but in installations where the cable method is not suitable,
e.g.insufficient space behind the firebox, or loose masonry, the firebox can be fit-
ted directly to either the front of the fireplace via the flange with the four off screws
provided. The firebox will require sealing to the fireplace however.
Flue
Inner Leaf of
brickwork
Outer Leaf of
Brickwork
Wall Cavity
Purpose Shaped gas
supply pipe supplied for
R/H entry
12

To secure the fire using the preferred cable method, proceed as follows :-
a) Mark out and drill 3 off No 14 6mm holes in the rear face of the fire
opening in the positions as shown on fig. 10 below.
Fig. 10
b) Fit the wall plugs provided and screw the fixing eyes securely into the
rear of the fire opening.
c) Uncoil the two fire fixing cables and thread one end of the each of the
cables through the rear of the fire box, and through each fixing eye at
the top. Thread both cables through the fixing eye at the bottom.
d) Thread the cables through the rear of the firebox, insert the flue pipes
through the hole in the rear of the wall and offer the firebox up to the
fireplace.
e) Thread the cables through the bracket which is situated on the base.
f) Thread a tensioning screw over both 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.
g) 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 11 overpage.
500mm
20mm
250mm
Fire Opening
13

Fig. 11
h) Before making the final gas connection, thoroughly purge the gas
supply pipework to remove all foreign matter, otherwise serious
damage may be caused to the gas control valve on the fire.
Failure to purge the gas supply will invalidate the guarantee.
i) The gas connection should be made to the appliance inlet elbow to
using 8mm rigid tubing.
j) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
k) Turn on the main gas supply and carry out a gas soundness test.
l) 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.
m) Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.) for FBFN**G models or 37.0 mbar (+/- 1.0mbar) 14.8 in
w.g.(+/- 0.4 in w.g.)
n) 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.
14

2.8 PREPARATION FOR MOUNTING THE F UE TERMINA
a) Position the flue terminal over the inner and outer flue pipes as shown
on fig. 12 below, checking that the outer pipe has the seam flange at
the bottom and the inner pipe has the seam flange at the top.
Fig. 12
b) Having positioned the terminal so that it is square to the wall, mark the
position of the mounting bracket holes on the outer wall, using the
terminal as a template. Remove the flue terminal and drill the 2 off
holes 6mm diameter into the wall. Insert the raw plugs Replace the
terminal onto the flue pipe and secure using the No.12 x 40mm screws
provided. See fig. 13
Fig. 13
NOTE : In England & Wales, the building regulations require that a terminal
guard should be fitted if the terminal could come into contact with people
near the building or be subject to damage. BFM Europe also recommend the
fitting of a flue terminal guard where regulations do not demand that it be
fitted. A suitable flue terminal guard is supplied with the appliance.
15

2.9 FITTING THE TERMINA GUARD
With the flue terminal in position, place the terminal guard over the top of the flue
terminal and mark the position of the holes on the outer wall. Remove the terminal
guard and drill the 4 off 6 mm holes. Insert the raw plugs into the drilled holes,
replace the terminal guard over the top of the flue terminal and attach to the wall
using the No.12 x 40mm screws provided with the terminal guard. See Fig. 14
below.
Fig. 14
2.10 REMOVING & REFITTING OF THE G ASS FRAME.
Fig. 15
16
op Infill Panel
4 x 6mm Allen Bolts

2.10 REMOVING & REFITTING OF THE G ASS FRAME (Continued)
a) Remove the 2 screws which hold the pilot shield in place. (see fig. 15)
b) Remove the top infill panel by sliding it upwards out of the clips.
c) With the allen key provided remove the 4 allen bolts, loosening each
one a small amount at a time to prevent stressing the glass panel, then
lift the glass frame clear.
d) Assemble ceramic fuel-bed and coals as shown in section three.
e) Refit the glass panel to the fire in reverse order, again tightening each
allen bolt a small amount at a time to prevent stressing the glass panel.
f) Fit the allen key to the bracket which is situated at the bottom left hand
corner of the firebox, and advise the customer of the position of the
allen key.
NOTE : Always ensure that a consistent seal between the combustion cham-
ber and the glass frame is achieved.
SECTION 3
ASSEMB ING FUE BED AND COMMISSIONING
3.1 FITTING THE FUE BED
a) Place the fuel-bed centrally onto the fuel-bed support. Ensure that the
fuel-bed is located centrally in the firebox, and that the front outside
face of the left and right hand fuel-bed legs are touching the stainless
steel fibre support trims. See Fig. 16
Fig. 16
17

b) Fit the heat deflector plate onto the stainless steel fibre support trims,
as shown below (fig. 17 & 18)
Fig. 17
Fig. 18
Refit the glass frame as detailed in section 2.10, then light the appliance as
detailed in section 3.2.
To ensure that the release of fibres from these R.C.F (Refractory Ceramic
Fibre) articles is kept to a minimum, during installation and servicing we
recommend that you use a HEPA filtered vacuum to remove any dust
accumulated in and around the appliance before and after working on the
appliance. When replacing these articles we recommend that the replaced
items are not broken up, but are sealed within heavy duty polythene bags,
clearly labelled as “RCF waste”. RCF waste is classed as a “stable”, non
reactive hazardous waste and may be disposed of at a landfill licensed to
accept such waste Protective clothing is not required when handling these
articles, but we recommend you follow the normal hygiene rules of not
smoking, eating or drinking in the work area, and always wash your hands
before eating or drinking.
18

3.2 IGHTING THE APP IANCE
IMPORTANT : IF THE BURNER IS EXTINGUISHED FOR ANY REASON YOU
MUST ENSURE THAT YOU WAIT A FU FIVE MINUTES BEFORE ATTEMPT-
ING TO RE- IGHT THE FIRE.
a) Turn on the gas restrictor at the inlet fitting.
b) 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.
c) Continue to hold-in the control knob and press the igniter button. If the
burner does not light, continue to press the igniter button until ignition
occurs. Continue to hold the control knob for 5-10 seconds to allow
thermocouple to heat up, if the pilot goes out when the control knob is
released, repeat the lighting sequence.
d) Turn the control knob in the anti-clockwise direction to the high position
and the main burner will light.
e) Turn the control knob clockwise to the low position and the gas input
will be reduced to the minimum setting.
f) Slightly depress the control knob and turn to the pilot position, the main
burner will go out but the pilot will remain lit.
g) Slightly depress the control knob and turn to the off position, the pilot
will now be extinguished.
h) 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.
WHEN TURNING THE FIRE “OFF” P EASE ENSURE THAT THE CONTRO
VA VE IS TURNED TO THE “OFF” POSITION AND THE PI OT F AME IS
EXTINGUISHED. DO NOT EAVE THE PI OT F AME ON Y IT.
3.3 FITTING THE TRIM & FRET
a) Push the decorative trim onto the magnets on the fire body, and secure
in place. Remove the protective trim before use.
b) The firebox is supplied with 2 fender fixing brackets and screws which
should be fixed to the holes in the fender, the flanges on the brackets
should be facing towards the outside of the fender.
c) Place the fender in position by locating the fender brackets between the
trim and the fire body.
d) ocate the ashpan cover.
Finally, hand the Installation and Maintenance Instructions and the Users
Instructions over to the customer and explain the operation of the fire.
NOTE : THIS APP IANCE IS DESIGNED TO WORK SAFE Y AND
EFFECTIVE Y DURING ADVERSE WEATHER CONDITIONS.
HOWEVER, DURING SUCH TIMES F AME DISTURBANCE MAY BE
NOTICED. THIS IS NORMA AND DOES NOT EFFECT OR IMPAIR
THE SAFETY OF THE APP IANCE.
19

SECTION 4
MAINTENANCE
Servicing Notes
Servicing should be carried out annually by a competent person such as a
CORGI registered engineer. It is a condition of Flavel Fires guarantee
schemes that this is carried out by a competent person i.e a CORGI
registered Engineer in accordance with these servicing notes
The condition of the coals should be checked and if necessary the whole set
should be replaced with a genuine replacement set.
The burner assembly is designed to be removed as a complete unit for ease of
access. After any servicing work a gas soundness check must always be
carried out.
4.1 Removing the burner assembly from the fire.
4.1.1 Remove Ash-pan, Fret assembly & Trim from the front of the fire.
4.1.2 Isolate the gas supply, remove the glass frame as shown on page 17,
then remove the 2 off fixing screws which hold the pilot shield in place.
4.1.3 oosen the pilot pipe, disconnect the ignition lead from the electrode
and disconnect the thermocouple from the pilot assembly.
4.1.4 Remove the 12 off fixing screws which hold the pilot mounting panel &
control panel in place.
4.1.5 ift the pilot panel upwards and away from the pilot pipe, taking care not
to damage or misplace the pilot injector, which is contained within the
pilot body.
4.1.6 oosen the burner pipe, which is situated below the burner to the left-
hand-side, from the bulkhead fitting.
4.1.7 Remove the 4 off fixing screws which attach the burner to the firebox
via fixing brackets.
4.2 Removing the Piezo Igniter
4.2.1 Remove Ashpan, Fret assembly & Trim from the front of the fire.
4.2.2 Isolate the gas supply, remove the glass frame, then remove the 2 off
fixing screws which hold the pilot shield in place.
20