Kohlangaz Gosford Plus Mounting instructions

Gosford Plus
INSET LIVE FUEL-EFFECT GAS FIRES
Installation, aintenance & User Instructions.
Hand these instructions to the owner following installation, they
must be retained for future reference.
odel No’s HOPC** N2, HOPC**SN2, HOPC**TN2 & HOPC**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 9
1.8 Hearths 9
1.9 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) 18
2.5 Gas tightness and inlet pressure (remote / electronic fire control models) 19
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 20-23
3.2 Fixing the Infra-red eye in position 23-24
3.3 Connecting the battery pack 25
3.4 Fitting the trim 25
3.5 Fitting the fender 25
3.6 Lighting the appliance (manual control models) 26
3.7 Lighting the appliance (slide control models) 27
3.8 Lighting the appliance (remote control models) 28
3.9 Lighting the appliance (electronic fire control models) 29
3.10 Checking for clearance of combustion products 30-31
Section 4 aintenance
4.1 Removal of the burner assembly (manual control models) 32
4.2 Removal of the piezo igniter (manual control models) 32
4.3 Removal of the control tap (manual control models) 33
4.4 Removal of the pilot assembly (manual control models) 33
4.5 Removal of the burner assembly (slide control models) 33-34
4.6 Removal of the battery igniter (slide control models) 34
4.7 Replacing the battery (slide control models) 34
4.8 Removing the oxy-pilot assembly (slide control models) 35
4.9 Replacing the control cable (slide control models) 35-36
4.10 Removal of the burner assembly (remote & electronic fire control models) 37
4.11 Removal of the valve (remote & electronic fire control models) 37
4.12 Removal of the oxy-pilot assembly (remote & electronic fire control models) 37-38
4.13 Replacing the batteries (remote & electronic fire control models) 38
4.14 Removal of the trim switch (electronic fire control models) 38
Part Shortlist / Fret Information 39
Section 5 User Instruction Section
5.1 Conditions of Installation & about your new fire 40-41
5.2 Operating the fire (manual control models) 42
5.3 Operating the fire (slide control models) 43-44
5.4 Operating the fire (remote control models) 44-45
5.5 Operating the fire (electronic fire control models) 45-46
5.6 Remote handset / EFC trim switch malfunction 47
5.7/5.8 Replacing the batteries in slide and remote / electronic fire control models 48
5.9 Spillage monitoring system 48
5.10 Cleaning instructions 49
5.11 Re-assembling the ceramics and fuel bed 50-53
2

SECTION 1
INFOR ATION AND REQUIRE ENTS
1.0 APPLIANCE INFOR ATION
Model HOPC**MN2 (MC)
HOPC**SN2 (SC)
HOPC**RN2 (RC)
HOPC**TN2 (EFC)
Gas Type G20
Main injector (1 off) Cat 960, size 2.0mm
Pilot Type Copreci
21100 / 141 (MC)
21100 / 162 (SC, RC & EFC)
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)
1.5V Battery Generator (SC models)
9V Battery Generator (RC & EFC models)
Electrode Spark Gap 4.5mm Nominal
Weight 18kg
This appliance is manufactured by:-
BFM Europe Ltd,
Trentham Lakes,
Stoke-on-Trent,
ST4 4TJ.
3

Fire box dimensions (with standard trim fitted)
Width : (with trim, no spacer) 498mm
Height : (with trim, no spacer) 600mm
Depth : (overall-without fender) 230mm
Gas Connection 8mm Compression (Supplied with fire)
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2009 and the result is 66%. 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 U
Governments Standard Assessment Procedure (SAP) for energy rating of
dwellings.
4

INSTALLATION REQUIRE ENTS
1.1 CONDITIONS OF INSTALLATION
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 FLUE AND CHI NEY SUITABILITY
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.
inimum diameter of circular flues 125 mm (without flue
restrictor fitted)
inimum 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 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
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 SHELF 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 FLUE / CHI NEY 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 PLACE OPENING AND CHI NEY CATCH ENT SPACE
The front opening of the fire place must be between 400 and 450 mm 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
400mm Minimum
450mm Maximum
580mm
Minimum
470mm Minimum
Fig. 1
550mm Minimum
570mm Maximum
Minimum Flat
Sealing Area
7

Table A - Installation Depth Re uirements for a Kohlangaz Gosford Plus
being installed into a brick built chimney, re uiring 12.0 litres of debris
collection volume (figure 2)
Opening Width (mm) Minimum Depth Required (mm)
400 (minimum opening width) 298
410 392
420 285
430 280
440 273
450 (maximum opening width) 269
For example, if the appliance was to be fitted into a 400mm wide opening, the
depth required would be 298mm. See figure 2 below for explanatory diagram.
Fig. 2
8
Opening Width ( e.g. 400mm)
Depth Required
(e.g. 298mm
minimum)

1.7 FITTING TO PRE-FABRICATED TWIN WALL ETAL FLUE 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.
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. EFC models required an increased hearth
projection of 320mm forwards of the fireplace opening.
1.9 SPILLAGE ONITORING SYSTE
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
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 20 coals (9 large square, 9
large random and 2 small square) coals
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 45mm grommet (all models)
1 off Installation & user instruction book (all models)
1 off Battery pack (RC & EFC models only)
6 off 1.5V batteries (RC & EFC models only)
1 off 9V battery (RC models only)
1 off 1.5V battery (SC models only)
1 off Guarantee card (all models)
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 of 3 metre minimum
effective flue height.
175mm (7 inch) diameter lined brick or stone flue, insulated pre-fabricated
metal flue box to BS 715 / BS EN 1856-2 of 3 metre minimum effective flue
height.
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 :-
a) Remove the burner heat shield from the front of the fire box to allow
access to the burner. See figure 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 figure 4 below.
Fig. 4
11

For slide control models proceed as follows:
d) Remove the burner heat shield from the front of the fire box to allow
access to the burner. See figure 5 below.
Fig. 5
e) 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.
f) Remove the burner. To allow burner removal, the control lever operat
ing 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 release the front part of the operating
arm, thereby freeing the cable from the burner. Not the securing screw
is retained in the block to prevent it from being lost. 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 figure 6 overpage
12

Fig. 6
g) Unscrew the burner assembly fixing screws at either side of the firebox,
and the two fixing screws at the base of the fire (see figure 7
below). Carefully pull the base of the burner forwards. The burner can
now be removed from the appliance.
Fig. 7
13

For remote & electronic fire control models proceed as follows:
h) Remove the trim. Remove the burner heat shield from the
front of the fire box to allow access to the burner. See fig. 8 below.
Fig. 8
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) 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 9 below.
Fig. 9
14

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 10 & 11 below for
suggested concealed pipe layouts.
Fig. 10
Fig. 11
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.
I PORTANT : THE 45 GRO ET SUPPLIED IN THE LOOSE ITE S UST BE USED
TO SEAL THE GAS INLET POINT UTILISED ON THE FIREBOX. FAILURE TO SEAL
THIS INLET POINT COULD RESULT IN FLA E REVERSAL AND DA AGE TO THE
CONTROLS ON THE FIRE. BF EUROPE ACCEPT NO RESPONSIBILITY FOR
DA AGE TO THE FIRE AS A RESULT OF FAILURE TO FOLLOW THIS REQUIRE ENT.
15
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-
h) 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 12
Fig. 12
Fit the wallplugs provided and screw the fixing eyes securely into the rear of the
fire opening.
i) 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.
j) 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.
k) 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).
l) 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 13 overpage.
16
20mm
500mm Fireplace Opening
100mm
250mm

Fig. 13
m) 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.
n) 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.
o) Refit the burner. Fit the four retaining screws and check that the burner
is correctly locked into position. On slide control models refit the control
cable. To do this, firstly locate the nipple on one end of the cable into
recess in operating arm and then secure the front part of the operating
arm back onto the rear of the operating arm with the retained screw.
This should not be overtightened. Move the control lever fully
downwards and check that the left hand micro-switch operates the
igniter and that the control valve spindle is fully depressed. Move the
control lever upwards to the “off” position and check that the control
lever operates smoothly and safely.
NOTE : The cable is factory set, and therefore should need no adjustment
p) Refit the front burner heat shield to the sides of the fire box (2 screws)
17

q) 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.
2.3 GAS TIGHTNESS AND INLET PRESSURE - ANUAL CONTROL
ODELS.
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
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.
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.
2.4 GAS TIGHTNESS AND INLET PRESSURE - SLIDE CONTROL
ODELS.
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.
18

2.5 GAS TIGHTNESS AND INLET PRESSURE - RE OTE CONTROL
OR ELECTRONIC FIRE CONTROL ODELS
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) Light the fire, see page 28 / 29 for full details of the operating method
for the fire.
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
ASSE BLING FUEL BED AND CO ISSIONING
3.1 ASSE BLING THE CERA ICS AND FUEL BED
a) Place the ribbed ceramic fuelbed base on top of the fuelbed support
and pull fully forwards to the burner. ake 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 14 below.
Fig. 14
b) 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 15 below)
Fig. 15
20