ORTAL Clear 150 Tunnel User manual

Installation and Operation Manual – AU/NZ
(For 150 – 250 Units)
ORTAL Heating Systems Ltd.

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ORTAL Heating Solutions Ltd.
INSTALLATION & OPERATION MANUAL
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly, could
result in serious injury, death, or property
damage.
DO NOT PLACE ARTICLES ON OR AGAINST THIS APPLIANCE.
DO NOT USE OR STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER
APPLIANCE.
DO NOT SPRAY AEROSOLS IN THE VICINITY OF THIS APPLIANCE WHILE IT IS IN OPERATION.
DO NOT MODIFY THIS APPLIANCE.
DANGER: IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone in your building.
Leave the building immediately.
Immediately call you gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
SAVE THESE INSTRUCTIONS
Make yourself fully aware of all the following instructions and the many features of the
Ortal room sealed gas fireplace appliance. DO NOT DISCARD THIS MANUAL!
INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference
Installation and service must be performed by
a qualified/authorized installer, service
agency, or the gas supplier. INSTALLER: test
the operation of the appliance before leaving.

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Testing Standards and Document Information
The ORTAL decorative room sealed gas appliances have been tested and approved by AGA for use with
Natural Gas (NG).
Standard references:
Australian Standard AS5263-0:2016 - Decorative Gas Log and Other Fuel Effect Appliances
Patent Pending for screen barrier glass bracket: USSN 60/040,074
NOTE: Diagrams and illustrations in this manual are not to scale. All fireplace drawings with correct
dimensions are available on our website under Products>Downloads>Diagram.
NOTE: For additional details about installing CC units and/or units with Power Flues, please refer to
the specific manuals supplied with the product.

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Table of Contents
Introduction and Company Profile .................................................................................................................. 7
Fireplace Safety Information and Warnings .............................................................................................. 8
Certifications and Codes .......................................................................................................................... 10
Product List: Models and Burners ........................................................................................................... 11
Fireplace Clearances ..................................................................................................................................... 13
Appliances and Flue Clearances: Overview ............................................................................................. 14
Concepts and Definitions ................................................................................................................... 14
Firebox Clearance Diagrams .................................................................................................................... 16
Diagrams for Mantel Clearances and Shelf Details ................................................................................. 18
Mounting of Console Appliance Models ................................................................................................. 20
Recommendations for Wall Mounting .............................................................................................. 20
Console Appliance Installation Diagrams........................................................................................... 24
Cool Wall Technology .............................................................................................................................. 26
Television and Fireplace Installation ....................................................................................................... 28
TV Placement Considerations ............................................................................................................ 28
TV Installation Clearance Diagrams ................................................................................................... 28
ORTAL Fireplaces with Double Glass ....................................................................................................... 31
Wall Support Sample Detail ..................................................................................................................... 33
Gas Setup ...................................................................................................................................................... 34
Gas Line Routing ...................................................................................................................................... 41
Control Connections .......................................................................................................................... 41
Gas Control Assemblies and Components ............................................................................................... 42
Pilot and Thermocouple Maintenance .................................................................................................... 43
Flue System Information ............................................................................................................................... 54
Flueing Requirements.............................................................................................................................. 55
Flueing Diagrams ..................................................................................................................................... 56
Flueing Diagram: Typical Horizontal .................................................................................................. 57
Flueing Diagram: Typical Vertical ....................................................................................................... 58
Flueing Diagram: Straight Vertical ..................................................................................................... 60
Working with Vertical Elbows ................................................................................................................. 61
Fireplace Restrictors and Flue Arrangement ........................................................................................... 64
Flue Installation and Clearances .............................................................................................................. 66
Flue Termination Drawings ..................................................................................................................... 67
Flue Maintenance .................................................................................................................................... 68
Fireplace Installation Instructions ................................................................................................................. 69
Selecting a Location ................................................................................................................................. 70
Installation Sequence .............................................................................................................................. 71
Working with Glass Panels ...................................................................................................................... 73
Fireplace Heat Barrier .............................................................................................................................. 74
Removal / Assembly of the Double Glass Heat Barrier and Inner Glass.................................................. 75

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Removing/Assembling Double Glass Heat Barrier and Inner Glass (Type 1) ..................................... 75
Removing/Assembling Double Glass Heat Barrier and Inner Glass (Type 2) ..................................... 81
Removal / Assembly of the Framed Screen ............................................................................................. 89
Removal / Assembly of the Protective Screen ........................................................................................ 93
Removing/Assembling the Inner Glass (Screen Heat Barrier Units) ........................................................ 97
Removing/Assembling the Back Panel .................................................................................................. 101
75/65 Front Bricks Installation .............................................................................................................. 105
Traditional Bricks Installation ................................................................................................................ 107
Remote Control Setup and Operation ................................................................................................... 111
Radio Frequency Handset ................................................................................................................ 112
Setting the Electronics Code ............................................................................................................ 112
Batteries ........................................................................................................................................... 113
Operating Instructions ..................................................................................................................... 114
Interior Design Media ............................................................................................................................ 116
Media Placement Guidelines ........................................................................................................... 116
Cold Climate Insulation ......................................................................................................................... 118
Post-installation Procedures ................................................................................................................. 119
Initial Burning Period ....................................................................................................................... 119
Final Inspection Procedure .............................................................................................................. 119
Final Checks and Customer Instruction ........................................................................................... 119
Operating Warnings .................................................................................................................................... 120
Maintenance Instructions ........................................................................................................................... 121
General Maintenance: Tips and Warnings ............................................................................................ 122
Maintenance Frequency and Equipment Checklist ............................................................................... 123
Thermocouple Maintenance ........................................................................................................... 123
Recommended Maintenance Equipment ........................................................................................ 123
ORTAL Factory Recommended Service Checklist .................................................................................. 124
ORTAL Product Service Log.................................................................................................................... 125
Manufacturer Contact Information ............................................................................................................ 126
Appendix A: Fireplace Troubleshooting Guide............................................................................................ 127
Pre-troubleshooting Checklist ............................................................................................................... 128
Normal Sequence of Fireplace Operation ............................................................................................. 130
Troubleshooting Pilot Problems ............................................................................................................ 131
Spark But No Pilot ............................................................................................................................ 131
No Spark to the Pilot ........................................................................................................................ 131
Pilot Turns Off After Igniting But Before Burner Turns On .............................................................. 131
Pilot Turns Off After Igniting and After Burner Turns On ................................................................ 132
Troubleshooting Thermocouple Problems ............................................................................................ 133
Checking the Thermocouple ............................................................................................................ 133
Testing the Thermocouple ............................................................................................................... 133
Troubleshooting Main Burner Problems ............................................................................................... 134
Troubleshooting Flame Issues ......................................................................................................... 135
Troubleshooting Beeping ...................................................................................................................... 136

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Mertix Maxitrol External Source Operation .......................................................................................... 138
Appendix B: Removal / Assembly of the Burner ......................................................................................... 139
Appendix C: Removal / Assembly of the Burner Base ................................................................................. 142
Table of Figures
Figure 1: Mantel Clearances: Recess and Flush Finishes ....................................................................... 18
Figure 2: Shelf Detail ............................................................................................................................. 19
Figure 3: Concrete Wall Mounting Detail .............................................................................................. 21
Figure 4: Wood Stud Mounting Detail .................................................................................................. 23
Figure 5: Console Appliance Front Facing Models ................................................................................ 24
Figure 7: 75 TS Console Appliance: Rear View ...................................................................................... 25
Figure 9: Fireplaces with Flush Finish: TV Clearances ........................................................................... 29
Figure 10: Fireplaces with Recess Finish: TV Clearances ....................................................................... 30
Figure 11:Chase Cavity Air Intake Options ............................................................................................ 31
Figure 12: Wall Support Sample Detail ................................................................................................. 33
Figure 13: Thermocouple Injector ......................................................................................................... 53
Figure 14: Flueing Diagram: Typical Horizontal ..................................................................................... 57
Figure 15: Flueing Diagram: Typical Vertical ......................................................................................... 59
Figure 18: Glass Seal Assembly Diagram ............................................................................................... 73
Figure 19: Double Glass: Parts............................................................................................................... 76
Figure 20: Double Glass Heat Barrier: Parts .......................................................................................... 81
Figure 21: Framed Screen Assembly: Parts ........................................................................................... 89
Figure 22: Protective Screen: Parts ....................................................................................................... 93
Figure 23: Inner Glass: Parts .................................................................................................................. 97
Figure 24: Back Panel: Parts ................................................................................................................ 101
Figure 25: Components for Front Bricks Installation .......................................................................... 105
Figure 26: Components for Traditional Bricks Installation .................................................................. 107
Figure 27: Log Media Placement for Clear 150 H F/RS/LS/TS/TU/SC, 170 H F/RS/LS/TS/TU .............. 117
Figure 28: Log Media Placement for Clear 200 H F/RS/LS/TS/TU/SC, Clear 200 F/RS/LS/TS/TU/SC .. 117
Figure 29: On/Off and Manual Pilot Valve Switches ........................................................................... 128
Figure 30: Valve/Receiver Wires and Interrupter Block ...................................................................... 129
Figure 31: ORTAL Remote Control ...................................................................................................... 130
Figure 32: Burner Components ........................................................................................................... 139
Figure 33: Burner Base Components ................................................................................................... 142
Table of Tables
Table 1: Wall Temperatures Above the Firebox .................................................................................... 26
Table 2: Material Damage Caused by Excessive Heat ........................................................................... 26
Table 6: Restrictor Table: Burner 135 – Series 150/170 ....................................................................... 65
Table 7: Restrictor Table: Burner 160 – Series 200-250 ........................................................................ 65

Introduction and Company Profile
Welcome to ORTAL.
ORTAL, providing heating solutions for over 25 years, is well known for its wide selection of modern gas
fireplaces, produced with close attention to detail, finishing, heating efficiency and quality. ORTAL’s products
combine traditional and modern design with the technology innovation that ensures a green product with high
efficiency ratings. Our advanced technology produces eye catching fires that are safe, beautiful and economical.
Our product sophistication allows installation in more locations inside the home.
ORTAL offers the largest selection of modern gas fireplaces in Australia & New Zealand available in an array of
sizes to suit design and architectural needs integrating heat into the aesthetics of life. ORTAL also welcomes
clients’ visions for custom-made fireplaces for special requirements, sizes and uses. Our high quality fireplaces are
CSA, AGA and CE certified. ORTAL fireplaces are available in Australia & New Zealand through ORTAL approved
dealers who each have a strong commitment to offer the best installation and service.
Green Statement: ORTAL offers a green, environmentally friendly heating solution for the modern era.
With ORTAL’s high efficiency ratings and contemporary designs, you don’t have to sacrifice form for function. The
unique design maximizes the fireplace’s radiant heat. Additional efficient components include ORTAL’s use of
room sealed technology, electronic ignition (instead of a standing pilot) and low maintenance requirements.
We appreciate you choosing ORTAL for your fireplace needs.
Thank you,
Ortal

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Fireplace Safety Information and Warnings
This section provides safety guidelines and instructions. It is important to SAVE THESE INSTRUCTIONS and to
make yourself fully aware of all the safety protocols and the many features of the ORTAL room sealed gas
fireplace appliance.
INSTALLER: Leave this manual with the appliance.
OWNER: Keep this manual for future reference.
NOTE: ALL the warnings and instructions below apply to ALL the models.
WARNING – HEAT BARRIER
A barrier designed to reduce the risk of burns from hot viewing glass is provided with this appliance and shall
be installed. If the barrier becomes damaged, the barrier shall be replaced with the manufacturer’s barrier
for this appliance. Any safety screen, guard, or barrier removed for servicing the appliance must be replaced
prior to operating.
THE BARRIER IS FITTED TO THIS APPLIANCE TO REDUCE THE RISK OF FIRE OR INJURY
FROM BURNS AND NO PART OF IT SHOULD BE PERMANENTLY REMOVED.
FOR PROTECTION OF YOUNG CHILDREN OR THE INFIRM, A SECONDARY GUARD IS
REQUIRED
WARNING – FIREPLACE TEMPERATURE
Due to high temperatures, the appliance should be located out of traffic and away from furniture and
draperies.
Children and adults should be alerted to the hazards of high surface temperature and should stay away to
avoid burns or clothing ignition.
Clothing or other flammable material should not be placed on or near the appliance.
Young children should be carefully supervised when they are in the same room as the appliance.
Toddlers, young children and others may be susceptible to accidental contact burns. A physical barrier is
recommended if there are at-risk individuals in the house. To restrict access to a fireplace or stove, install an
adjustable safety gate to keep toddlers, young children and other at-risk individuals out of the room and
away from hot surfaces.

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WARNING – GLASS HANDLING
The glass must ONLY be removed by an authorized installer. The authorized technician should ONLY remove
the glass with the suction cups supplied by the manufacturer. To prevent damage to the glass edges, lower
the glass to rest in a safe place.
Follow these guidelines for glass handling:
Step 1: Prepare a safe place for the glass to rest.
Step 2: Remove the glass using the suction cup.
Step 3: The glass can now be rested safely.
WARNING – IF YOU SMELL GAS
If you smell gas, take the following action immediately:
Do not try to light any appliance.
Do not touch any electrical switch.
Do not use any phone in your building.
Call your gas supplier from a neighbor’s phone, and follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
WARNING – INSTALLATION AND OPERATION
The room sealed system appliance must be installed as an OEM installation in manufactured homes or an
aftermarket permanently located, or a mobile home, where not prohibited by local codes.
The appliance must be installed in accordance with the Manufacturer's instructions and the Manufactured
Home Construction and Safety Standard.
If the information in these instructions are not followed exactly, a fire or explosion may result, causing
property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this appliance.
WARNING – INSTALLATION AND SERVICE
Installation and repairs must be done by an authorized installer service agency or gas supplier. The appliance
should be inspected before use and at least annually by a professional service person. More frequent
cleaning may be required due to excessive lint from carpeting, bedding material, etc. It is imperative that
control apartments, burners and circulating air passageways of the appliance be kept clean.
Any alteration to the product that causes soot or carbon to form and results in damage is not the
responsibility of the manufacturer.
WARNING – GAS APPLIANCE
This appliance is for use only with the type of gas indicated on the rating plate. These appliances are not
convertible for use with other gases, unless a certified kit is used and the conversion is performed by an
authorized technician.

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Certifications and Codes
The appliance has been certified for use with either natural gas (NG) or Universal LPG, and NOT for use with solid
fuels.
These gas fireplace appliances are CSA certified and approved for indoor use. They can be specialized with certain
requirements for indoor outdoor use (i.e., tunnel models). For indoor installation they must be installed while
maintaining required clearances. Installation is recommended in living spaces such as bedrooms, living rooms,
great rooms, etc. The appliance is not approved for closet installation.
The appliance must be installed according to ORTAL requirements in addition to any local codes that may apply.
The appliance must be properly connected to an approved flueing system. Refer to the specific appliance to
determine flue size and pathway requirements. In addition, adhere to the following pre-installation guidelines:
Approved flue system manufacturers are:
DuraVent
Heat & Glo
Olympia
Consult the authority having jurisdiction to determine the need for a permit PRIOR to starting the
installation.
It is the responsibility of the installer to ensure that this fireplace is installed in compliance with the
manufacturer's instructions and all the applicable codes.
Before starting, take careful note of ALL the WARNINGS in this manual.

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Product List: Models and Burners
The following table lists burners and flueing for models using the installation codes for decorative flued gas
fireplaces. Adaptors are not required.
MODELS: FR/RS/LS/TS/SA/TU/H/TR/SC
Model
Clear 150/170, Space Creator 150
Clear 200/250, Space Creator 200
Gas
NG
Universal LPG
NG
Universal LPG
Burner Size
135D
135D
160D
160D
Injectors
Marked 1200:
with
7x1.25mm
orifice
Marked 1400:
With single
3.9mm orifice
2xMarked 260
with
7x0.58mm orifice
Marked
800: with
7x1.05mm
orifice
Marked
1400:
With
single
3.8mm
orifice
2xMarked 260 with
7x0.78mm orifice
Nominal gas
Consumption
55 MJ/h
50 MJ/h
52 MJ/h
40 MJ/h
Inlet Pressure
1.13kPA
2.75kPa
1.13kPA
2.75kPa
Manifold pressure
0.61kPA
2.3kPa
0.50kPA
1.6kPa
Turndown Pressure
0.22kPa
1.5kPa
0.22kPa
0.87kPa
The following table lists flue sizes for decorative flued gas fireplaces.
BURNER
MODELS: FR/RS/LS/TS/SA/TU/H/TR
Flue SIZE
B135
Clear 150, Clear 170, Space Creator 150
125/205mm
B160
Clear 200, Clear 250, Space Creator 200
125/205mm
The following table explains the acronyms used.

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FR
Front
RS
Right Side
LS
Left Side
TS
Three Sides
SA
Console Appliance
TU
Tunnel
H
High (For all modules)
TR
Traditional
SC
Space Creator

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Fireplace Clearances
This chapter provides information, diagrams and recommendations related to mounting, minimum clearances,
television installation and more:
Appliances and Flue Clearances: Overview on page 14
Firebox Clearance Diagrams on page 16
Diagrams for Mantel Clearances on page 18
Mounting of Console Appliance Models on page 20
Cool Wall Technology on page 26
Television and Fireplace Installation on page 28
ORTAL Fireplaces with Double Glass on page 31
Wall Support Sample Detail on page 33

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Appliances and Flue Clearances: Overview
The appliance is approved with maintained minimum clearance to combustible materials, as shown in the
diagrams provided in this chapter.
Non-combustible materials, such as surrounds and other appliance trim, may be installed on the appliance face
as long as the minimum clearances are maintained between the appliance and the non-combustible material.
Surrounding material is not allowed to transfer weight to the unit or be connected in any way to the unit, with
the exception of the Gyprock Fyrchek drywall (or its equivalent) in a flush install. It may be fastened to the frame
with 2.5cm self-tapping drywall screws 40cm on center, with a minimum of 6.5cm from the glass lip. It must not
transfer weight to the fireplace, or cover any portion of the removable glass panel or the control compartment.
The minimum clearances (air space) to combustible materials must be adhered to. It is of the greatest
importance that the fireplace and flue system be installed only in accordance with these instructions.
Concepts and Definitions
Access Panels: These are typically required for all ORTAL fireplaces. They allow for efficient and
comfortable access to the fireplace receiver and valves, which is required to service the unit(s). Also,
access panels can be uniquely placed and designed to not disturb the aesthetic incorporation of the
fireplace to its surrounding living space. The size of the Access Panel may vary, but in all cases must
allow the fireplace technician to effectively access and service the valve and receiver if required.
However, access panels are not the only option for servicing the fireplace operation mechanisms. A
technician may also service the fireplace controls by going through the firebox. This procedure requires
removing the glass panel(s), taking out the interior design media and lifting the grill, burner and bottom side
(explosion valve) of the unit. The technician would then return all these fireplace components when service is
complete.
Fireplace dealers/installers are advised to consult with their clients, project architects and/or interior
designers regarding the advantages and disadvantages of each service option.
Framing and Drywall: Fireplace chase may be framed with metal studs or wood studs. Wood must be
covered completely with non-combustible material and have the gaps sealed with a non-combustible
fire sealant. We recommend using 16mm Gyprock Fyrchek fire rated drywall or its equivalent for the
enclosure of the fireplace chase. The framing of the fireplace chase wall must be designed to carry the
entire weight of the wall. Plan to include weight of other finish materials placed on the drywall.
Heat Release: Heat release is required for all models except the Console Appliances. This allows for
heat building up within the fireplace chase to be released back into the space, helping to keep the
fireplace wall cool. It must be located at the top of the fireplace chase and be placed a maximum of 15
cm below the fireplace chase ceiling. It can be located on the front, sides or back of the fireplace chase,
as long as it is being released into an interior space and not outdoors. A minimum air space is required
per series:
Minimum 0.13 sq. meter. of free air space for Series 150-200
Minimum 0.16 sq. meter. of free air space for Series 250
These air space values are the minimum required- they can always be greater. The heat release can be added
as a louver or as a reveal. If using a louver, make sure that the free airspace allowed in the louvered area is
equal or greater than the minimum number of square meters required per unit.

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Fireplace Legs: All ORTAL built-in fireplaces (Clear Front, LS, RS, TS, and Space Creator) come standard
with legs that measure:
Protective screen units: 21cm from the bottom of the fireplace glass opening to the floor
This is the minimum height for the firebox to rest on the floor. The legs cannot be removed.
Console Appliance models come with legs that are used for transportation purposes only. These are
connected with a bolt that must be removed once the unit is installed onsite. Since these models do not have
legs, they can only be wall mounted.

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Firebox Clearance Diagrams
This manual is based on installation of front-facing ORTAL fireplaces. To install other ORTAL fireplace styles,
modify the instructions per ORTAL Framing Dimensions.
Maintain clearances as shown in the figures below. Clearances are to non-combustible materials, or 16mm
Gyprock Fyrchek fire rated drywall or its equivalent.
The legend for the figures is provided in the following table:
16mm Gyprock Fyrchek fire rated gypsum board
Section cut
Wood
Combustible material
Non-combustible material
Wood framing
Metal framing
FRONT/TRADITIONAL
TUNNEL (SEE-THRU)

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LEFT SIDE OPEN (LS)
RIGHT SIDE OPEN (RS)
THREE SIDES (TS)

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Diagrams for Mantel Clearances and Shelf Details
The following sections present clearance diagrams for different fireplace options. Please note that these drawings
are not to scale. All fireplace drawings with correct dimensions are available on our website under
Products>Downloads>Diagram
NOTE: For detailed information about framing and finishes, please refer to the Ortal Builder’s Manual.
Figure 1: Mantel Clearances: Recess and Flush Finishes
LEGEND:
16mm Gyprock Fyrchek fire rated
gypsum board (or equivalent)
Wood framing
Combustible material
Metal framing
Non-combustible materials: Materials applicable for the installation of ORTAL fireplaces within the specified
clearance dimensions are described as non-combustible materials. An exception is made only for fire rated 16mm
Gyprock Fyrchek gypsum wallboard UL authorized or equivalent, where a non-combustible material may be
used.
The air flow area must be free from any obstruction, to allow heat from the chase to be released.

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Figure 2: Shelf Detail
LEGEND:
16mm Gyprock Fyrchek fire rated
gypsum board (or equivalent)
Wood framing
Combustible material
Metal framing
Non-combustible materials: Materials applicable for the installation of ORTAL fireplaces within the specified
clearance dimensions are described as non-combustible materials. An exception is made only for fire rated 16mm
Gyprock Fyrchek gypsum wallboard UL authorized or equivalent, where a non-combustible material may be
used.
The air flow area must be free from any obstruction, to allow heat from the chase to be released.

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Mounting of Console Appliance Models
This section provides guidelines and diagrams related to mounting of Console Appliance models.
Recommendations for Wall Mounting
The following procedures present manufacturer-recommended instructions for mounting on concrete walls and
wood stud walls.
NOTE: All installations are to be completed per local building codes and safety requirements. The
recommendations provided do not take the place of reviewing and incorporating structural requirements set
forth by the building engineer, local codes, etc.
To mount the unit on a concrete wall:
1. Position the unit at the desired height and mark the wall. There should be a minimum 30cm and
maximum 75cm distance from the bottom of the unit to the floor.
2. Mount the Console Appliance hanging bracket using Hilti 9.5mm x 7.5mm KWIK BOLT 3 expansion
anchors (or equivalent) with manufacturer's requirement of 63mm embedment and torque to
20ft-lbs.
3. Attach the unit to the mounting bracket. (See Figure 3 on page 21).
WARNING: Console Appliances are Wall Mounted units ONLY.
They cannot be placed in closed surroundings like bookcases, cupboards or closed walls.