Global Fires Karara HE Mounting instructions

Karara HE
HIGH EFFICIENCY FUE EFFECT GAS FIRE
Installation, Maintenance & User Instructions
Hand these instructions to the user
Model No’s GSHC**MN, GSHP**MN, GSHC**SN & GSHP**SN are for
use on Natural Gas (G20) at a supply pressure of 20 mbar in G.B. /
I.E.
** denotes trim and fret variant fitted to product

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
1.6 Fire place opening / catchment space 6-7
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 10-18
2.3 Gas tightness and inlet pressure (manual control models) 18
2.4 Gas tightness and inlet pressure (slide control models) 19
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the coal fuelbed 20
3.2 Fitting the pebble fuelbed 20
3.3 Fitting the trim 21
3.4 Fitting the fret 21
3.5 Fitting the one piece fascia 22
3.6 ighting the appliance (manual control models) 22
3.7 ighting the appliance (slide control models) 23
3.8 Checking for clearance of combustion 24
products
Section 4 Maintenance
4.1 Removal of the burner assembly (manual control models) 25
4.2 Removal of the piezo igniter (manual control models) 25
4.3 Removal of the control tap (manual control models) 26
4.4 Removal of the thermocouple (manual control models) 26
4.5 Removal of the burner assembly (slide control models) 27
4.6 Removal of the battery ignitor (slide control models) 28
4.7 Replacing the battery (slide control models) 28
4.8 Removing the oxy-pilot assembly (slide control models) 28
4.9 Replacing the control cable (slide control models) 29-30
Section 5 User Instructions Section
5.1 Conditions of installation / about your new gas fire 31-32
5.2 Operating the fire (manual control models) 33
5.3 Operating the fire (slide control models) 34-35
5.4 Removal / replacement of the coal fuelbed 36-37
5.5 Removal / replacement of the pebble fuelbed 36-37
5.6 Cleaning the fire 38
This appliance is manufactured by :-
BFM Europe td.Trentham akes,
Stoke-on-Trent, ST4 4TJ
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APP IANCE INFORMATION
Model GSHC**MN / GSHP**MN / GSHC**SN /
GSHP**SN
** denotes trim & fret variant of product
Manual Control Slide Control
Gas Type G20 G20
Main injector (1 off) Size 152 Size 146
Pilot Type Aeromatic Self SIT NG 9055 ODS
Vitiating Burner
Max. Gross Heat Input : 4.0kW 4.0kW
Min. Gross Heat Input : 2.0 kW 2.0 kW
Cold Pressure : 20.0 +/-1.0 mbar 20.0 +/-1.0 mbar
Ignition : Push button piezo 1.5V Battery
Electrode Spark Gap 4.0mm 4.0mm
Packed Weight (All models with fret) 15.5 kg
Packed Weight (All models with Contemporary Trim) 13.5 kg
Fire box Dimensions (with trim fitted)
Width : (with trim fitted) 510mm
Height : (with trim fitted) 625mm
Depth : (from mounting face to rear panel) 125mm
Gas Connection : 8mm Compression (Supplied with fire)
Appliance Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2002 and the result is 80%.
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 G
Industrial Services UK td. The efficiency value may be used in the UK
Government’s Standard Assessment Procedure (SAP) for energy rating of
dwellings.
3

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 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 2 Installation of Inset Fuel Effect Gas Fires
2. B.S. 6891 Installation of Gas Pipework
3. B.S. 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. B.S. 1251 Open fire place components
5. B.S. 715 Metal flue pipes for gas appliances
6. B.S. 6461 Part 1 Installation of Chimneys and flues
7. B.S. E.N. 1858 Chinmeys Components & Concrete Flue Blocks
8. I.S. 813 : 1996 Domestic Gas Installation (Republic of Ireland)
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. It is also suitable for use with pre-cast flue blocks conforming
to B.S. E.N. 1858 and metal flue boxes conforming to BS 715. All flues must
conform to the following minimum dimensions.
Minimum diameter of circular flues 125 mm (Without Flue
Restrictor Fitted)
Minimum effective height of all flue types 3 metres
When fitting to conventional chimneys or 175mm flues it may be desirable to
leave the flue restrictor baffle (supplied) in place to reduce the flue flow and
increase the efficiency of the fire. Safe clearance of products must always
be checked by carrying out a smoke match test as described.
4

1.3 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. (Class “O”)
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. With pre-cast flues
it is especially important to check the inside of the flue for extruded
cement / sealant protruding from the joints between the flue
blocks. If present, these should be removed by rodding the flue
before proceeding with the installation.
5. Using a smoke pellet, check that there is an up-draught in the
chimney / flue and that the smoke can be seen issuing from the
terminal / chimney pot outside.
5

There must be no leakage of smoke through the structure of
the chimney during or after the smoke pellet test and it is
important to check inside upstairs rooms adjacent to the chimney /
flue. Check the chimney pot / terminal and general condition of the
brickwork or masonry. If the chimney or flue is in poor condition or if
there is no up-draught do not proceed with the installation. If there is a
history of down-draught conditions with the chimney / flue, a tested and
certificated flue terminal or cowl suitable for the relevant flue type should
be considered.
6. A spillage test must always be carried out during commissioning of
the appliance.
1.6 FIRE P ACE OPENING AND CHIMNEY CATCHMENT SPACE
The front opening of the fire place must be between 330 and 440 mm wide, and
between 550 and 575mm 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 in a conventional
brick built chimney or 2 litres of volumetric space in a pre-cast flue.
Fire Opening
330mm Minimum
440mm Maximum
600mm
Minimum
355mm Minimum
Fig. 1
550mm Minimum
575mm Maximum
Minimum Flat
Sealing Area
6

Table A - Installat on Depth Requ rements for a Global Karara HE be ng
nstalled nto a br ck bu lt ch mney, requ r ng 12.0 l tres of debr s collect on
volume (f g. 2).
Opening Width (mm) Minimum Depth Required (mm)
330 (minimum opening width) 152
340 149
350 146
360 144
370 142
380 139
390 137
400 135
410 132
420 130
430 127
440 (maximum opening width) 125
For example, if the appliance was to be fitted into a 400mm wide opening, the
depth required would be 135mm. See fig. 2 below for explanatory diagram.
Fig. 2
7
Opening Width ( e.g. 400mm)
Depth Required
(e.g. 135mm)

1.7 FITTING TO FIREP ACES WITH EXISTING CHAIRBRICKS AND
CONVENTIONA BRICKBUI T 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 175mm. If the depth is less than 175mm then the chairbrick
must be removed. 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 F UE INSTA ATIONS
When installing this appliance into pre-cast flues, always ensure that the
spigot restrictor baffle has been removed. This is held in place on the spigot
by 2 screws
To install the fire box in to pre-cast flue starter blocks, there must be at least
125mm from the mounting face of the fire to the rear of the pre-cast flue
starter block to allow sufficient space for debris collection. If this dimension is
less than 125mm then a fire surround with a deeper rebate to increase the depth
to at least 125mm from the mounting face of the fire. 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 125 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 D.F.A. td. 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 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.
1.9 FITTING TO PRE-FABRICATED TWIN WA META F UE 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 FE 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. 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 12mm with the top surface at
least 50mm above the floor. The hearth must be fitted symmetrically about the fire
opening and have a minimum width of 760mm and a minimum projection of
300mm forwards from the fire opening.
1.11 SPI AGE MONITORING SYSTEM
This appliance is fitted with an atmosphere sensing spillage monitoring system in
the form of an oxygen sensing burner. 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
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.
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 ist - Coal Fuelbed Models
1 off Fire box / burner assembly
1 off Boxed ceramic coal effect fuel-bed
1 off oose items bag.
1 off Trim (3 piece or 1 piece dependent upon model chosen)
1 off Boxed Fret & Ashpan cover (dependent upon model chosen)
1 off Installation / User book (Combined)
Packing Check ist - Pebble Fuelbed Models
1 off Fire box / burner assembly
1 off Boxed ceramic pebble effect fuel-bed
1 off oose items bag
1 off Chrome Effect Trim / Ashpan
1 off Installation / User book (Combined)
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, 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.
A spillage test must always be carried out to check satisfactory
clearance of flue products, regardless of the type of flue the
appliance is being fitted to.
10

Proceed as follows for all models, (manual control model shown) :-
a) Remove the top glass panel retaining trim which is held in position by 5
off screws as shown below in Fig. 3
b) Remove the left hand glass retaining trim as which is held in position by
3 screws as shown below in Fig. 3
c) Remove the right hand glass retaining trim as which is held in position
by 3 screws as shown below in Fig. 3
d) Remove the burner heat shield which is held in position by 2 screws as
shown below in Fig. 3
Fig. 3
11
Left Hand Glass Retaining
Bracket - 3 off screws
Right Hand Glass
Retaining Bracket -
3 off screws
Top Glass Panel Retaining
Trim - 5 off screws
Glass Panel
Burner Heat Shield
2 off screws

For all manual control models proceed as follows :-
e) Remove the two screws at the bottom of the control panel. See fig. 4
below. Remove the three screws from the fuel-bed base support as
shown below also in Fig. 4
Fig. 4
f) ift the burner engine clear as shown in Fig. 5 below
Fig. 5
2 screws
3 off screws
12

For all Slide Control models proceed as follows :-
g) Remove the burner. To allow burner removal, the control lever
operating cable must be removed. The control lever operating cable
can be seen running across the base of the fire, below the burner. To
release the cable, unscrew the cable securing screw located in the
centre of the aluminium operating arm and pull the cable out from its
fixing hole. Release the other end of the cable by pushing the cable
forwards to the right, i.e. into the operating arm so as to release the
tension. Pull the cable nipple out of the retaining hole and remove the
cable through the slot in the operating arm. See fig. 6 below.
Fig. 6
h) Remove the two screws at the bottom of the control panel. See fig. 7
below. Remove the two screws from the fuel-bed base support as
shown below also in Fig. 7
Fig. 7
13
2 off screws
2 screws

Continue as follows for all models :-
i) 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.
j) Whilst the fire box is still in position, decide which side the gas supply is
to enter the fire from. If concealed pipe work is required plan the pipe
run to enter the fire box through one of the openings in the sides or rear
of the fire box below the fuelbed support panel and connect to the
isolating / inlet elbow. The gas connection to the appliance should be
made to the isolating / inlet elbow using 8mm rigid tubing. There must
be no soldered joints within the firebox. See fig. 8 & 9 below for
suggested concealed pipe layouts.
Fig. 8
Fig. 9
Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound.
14
Fire ox
Approx.
40mm Fireplace
Gas Supply
Fire ox
Approx.
40mm Fireplace
Gas Supply

IMPORTANT : Sealing of the Gas Inlet Apertures
In line with current regulations, it is imperative that the gas supply inlet
aperture that is utilised during the installation is sealed with the grommet
as supplied in the loose items pack. The product is manufactured with 3 knock
out gas inlets in the firebox wrap to allow a left hand, right hand or rear gas inlet
supply to the inlet elbow. Using a hammer and a blunt chisel, remove the inlet
aperture selected and then seal with the grommet supplied. To provide access for
the gas supply pipe, cut the grommet with a sharp knife. Failure to seal the inlet
apertures could lead to flame reversal, which in turn will damage the burner and
control systems of the product.
Fig. 10 below shows a correctly sealed installation.
Fig. 10
PLEASE NOTE :-
15
D.F.A. TD. WI NOT BE IAB E FOR
GUARANTEE C AIMS THAT ARE AS A DIRECT
RESU T OF THE GAS IN ET APERTURE NOT BEING
CORRECT Y SEA ED WITH THE GROMMET
PROVIDED.
Grommet fitted and cut to
provide access for the gas
supply pipe.

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.
The preferred method of fixing which is suitable for almost all situations is
the cable fixing method which is described in the following section in detail.
The fire may be secured using the cable method as described below, or
alternatively, in installations where the cable method is not suitable (eg. loose
masonary in rear of fire opening) the fire box can be directly secured to the fire
surround using screw fixings (not provided).
To fit using the preferred cable method proceed as follows-
k) Mark out and drill 4 off No 14 (7mm) holes in the back face of the fire
opening in the positions shown below in fig. 11
Fig. 11
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.
l) 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.
m) Position the fire carefully on the (protected) surface of the hearth and
reach into the fire opening. Thread each of the cables vertically
16
Fireplace Opening
325mm
100mm
500mm
20mm

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.
n) 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).
o) 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. 12 below
Fig. 12
p) 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.
q) With the fire securely in place, if a concealed gas connection has been
made through either of the access holes in the sides or rear of the fire,
the holes should be closed around the pipe to prevent leakage of air
through the gap around the pipe.
r) Refit the burner. Fit the two retaining screws and check that the burner
is correctly locked into position.
s) 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.
17

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 (not provided). Below (Fig. 13) is a diagram to indicate the hole
centre positions available on the firebox to facilitate the screw fixing to the fire-
place / surround.
Fig. 13
2.3 GAS TIGHTNESS AND IN ET PRESSURE (MANUA CONTRO )
a) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
b) Turn on the main gas supply and carry out a gas tightness test.
c) Depress the control knob and turn anti-clockwise to the position marked
ignition / low. Hold in the control knob for a few seconds to purge the
pipe work then press the igniter button. The burner should light,
continue to hold the control knob for a few seconds then turn to the full-
on position.
d) Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.)
e) Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.
300mm
140mm
520mm
430mm
Fire ox
Mounting
Flange
18

2.4 GAS TIGHTNESS AND IN ET PRESSURE (S IDE CONTRO
MODE S).
a) Remove the pressure test point screw from the pressure test point and
fit a manometer.
b) Turn on the main gas supply and carry out a gas tightness 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 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.)
e) Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.
19

SECTION 3
3.1 Fitting the Coal Fuelbed (where applicable)
a) Place the coal fuelbed centrally on to the fuelbed support and push
fully backwards to the rear face of the fibre boards Make sure that the
fuelbed base is located centrally in the fire box. See Fig. 14 below.
Fig. 14
3.2 Fitting the Pebble Fuelbed (where applicable)
a) Place the pebble fuelbed centrally on to the fuelbed support and push
fully backwards to the rear face of the fibre boards Make sure that the
fuelbed base is located centrally in the fire box. See Fig. 15 below.
Fig. 15
20