ORTAL Clear 150 Tunnel User manual

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InstallationandOperationManual–AU/NZ
(For150–250Units)
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ORTALHeatingSystemsLtd.
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2
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ORTAL Heating Solutions Ltd.
INSTALLATION & OPERATION MANUAL
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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!
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.

3
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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 AS4558-2011 - Decorative Gas Log and Other Fuel Effect Appliances
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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...............................................................................................................9
FireplaceSafetyInformationandWarnings................................................................................................10
CertificationsandCodes.......................................................................................................................12
ProductList:ModelsandBurners.........................................................................................................13
FireplaceClearances...................................................................................................................................14
AppliancesandFlueClearances:Overview...........................................................................................14
ConceptsandDefinitions.................................................................................................................14
FireboxClearanceDiagrams..................................................................................................................16
DiagramsforMantelClearancesandShelfDetails................................................................................18
MountingofStandAloneModels.........................................................................................................20
RecommendationsforWallMounting.............................................................................................20
StandAloneInstallationDiagrams...................................................................................................24
CoolWallTechnology............................................................................................................................28
TelevisionandFireplaceInstallation.....................................................................................................29
TVPlacementConsiderations..........................................................................................................29
TVInstallationClearanceDiagrams.................................................................................................30
ORTALFireplaceswithDoubleGlass.....................................................................................................32
WallSupportSampleDetail..................................................................................................................34
GasSetup...................................................................................................................................................35
GasLineRouting...................................................................................................................................35
ControlConnections........................................................................................................................35
GasControlAssembliesandComponents.............................................................................................36
PilotandThermocoupleMaintenance..................................................................................................37
FlueSystemInformation............................................................................................................................38
FlueingRequirements...........................................................................................................................38
FlueingDiagrams..................................................................................................................................38
FlueingDiagram:TypicalHorizontal................................................................................................39
FlueingDiagram:TypicalVertical.....................................................................................................40
FlueingDiagram:StraightVertical...................................................................................................41

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WorkingwithVerticalElbows...............................................................................................................42
FireplaceRestrictorsandFlueArrangement.........................................................................................44
FlueInstallationandClearances............................................................................................................47
FlueTerminationDrawings...................................................................................................................48
FlueMaintenance.................................................................................................................................49
FireplaceInstallationInstructions...............................................................................................................50
SelectingaLocation..............................................................................................................................50
InstallationSequence............................................................................................................................51
WorkingwithGlassPanels....................................................................................................................52
FireplaceHeatBarrier...........................................................................................................................53
Removal/AssemblyoftheDoubleGlassHeatBarrierandInnerGlass.................................................54
Removing/AssemblingDoubleGlassHeatBarrierandInnerGlass(Type1).....................................54
Removing/AssemblingDoubleGlassHeatBarrierandInnerGlass(Type2).....................................60
Removal/AssemblyoftheFramedScreen...........................................................................................68
Removal/AssemblyoftheProtectiveScreen.......................................................................................72
Removing/AssemblingtheInnerGlass(ScreenHeatBarrierUnits).......................................................76
Removing/AssemblingtheBackPanel..................................................................................................80
75/65FrontBricksInstallation..............................................................................................................84
TraditionalBricksInstallation................................................................................................................86
RemoteControlSetupandOperation...................................................................................................90
RadioFrequencyHandset................................................................................................................91
SettingtheElectronicsCode............................................................................................................91
Batteries..........................................................................................................................................92
OperatingInstructions.....................................................................................................................93
InteriorDesignMedia...........................................................................................................................95
MediaPlacementGuidelines...........................................................................................................95
ColdClimateInsulation.........................................................................................................................96
Post‐installationProcedures.................................................................................................................97
InitialBurningPeriod.......................................................................................................................97
FinalInspectionProcedure..............................................................................................................97
FinalChecksandCustomerInstruction............................................................................................97

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OperatingWarnings...................................................................................................................................98
MaintenanceInstructions...........................................................................................................................98
GeneralMaintenance:TipsandWarnings.............................................................................................98
MaintenanceFrequencyandEquipmentChecklist...............................................................................99
ThermocoupleMaintenance...........................................................................................................99
RecommendedMaintenanceEquipment........................................................................................99
ORTALFactoryRecommendedServiceChecklist.................................................................................101
ORTALProductServiceLog.................................................................................................................102
WarrantyPolicy........................................................................................................................................103
ManufacturerContactInformation..........................................................................................................107
AppendixA:FireplaceTroubleshootingGuide..........................................................................................108
Pre‐troubleshootingChecklist.............................................................................................................108
NormalSequenceofFireplaceOperation...........................................................................................110
TroubleshootingPilotProblems..........................................................................................................111
SparkButNoPilot..........................................................................................................................111
NoSparktothePilot.....................................................................................................................111
PilotTurnsOffAfterIgnitingButBeforeBurnerTurnsOn.............................................................112
PilotTurnsOffAfterIgnitingandAfterBurnerTurnsOn...............................................................112
TroubleshootingThermocoupleProblems..........................................................................................113
CheckingtheThermocouple..........................................................................................................113
TestingtheThermocouple.............................................................................................................113
TroubleshootingMainBurnerProblems.............................................................................................114
TroubleshootingFlameIssues.......................................................................................................115
TroubleshootingBeeping....................................................................................................................116
MertixMaxitrolExternalSourceOperation.........................................................................................118
AppendixB:Removal/AssemblyoftheBurner.......................................................................................119
AppendixC:Removal/AssemblyoftheBurnerBase...............................................................................122
TableofFigures
Figure1:MantelClearances:RecessandFlushFinishes.....................................................................18
Figure2:ShelfDetail...........................................................................................................................19

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Figure3:ConcreteWallMountingDetail............................................................................................21
Figure4:WoodStudMountingDetail................................................................................................23
Figure5:StandAloneFrontFacingModels.........................................................................................25
Figure6:75TSStandAlone:Front,TopandSideViews.....................................................................25
Figure7:75TSStandAlone:RearView..............................................................................................26
Figure8:StandAloneBracketDrawings.............................................................................................27
Figure9:FireplaceswithFlushFinish:TVClearances..........................................................................30
Figure10:FireplaceswithRecessFinish:TVClearances.....................................................................31
Figure11:ChaseCavityAirIntakeOptions..........................................................................................32
Figure12:WallSupportSampleDetail...............................................................................................34
Figure13:ThermocoupleInjector.......................................................................................................37
Figure14:FlueingDiagram:TypicalHorizontal...................................................................................39
Figure15:FlueingDiagram:TypicalVertical.......................................................................................40
Figure16:FlueTermination:Horizontal.............................................................................................48
Figure17:FlueTermination:Vertical..................................................................................................49
Figure18:GlassSealAssemblyDiagram.............................................................................................52
Figure19:DoubleGlass:Parts............................................................................................................54
Figure20:DoubleGlassHeatBarrier:Parts........................................................................................60
Figure21:FramedScreenAssembly:Parts.........................................................................................68
Figure22:ProtectiveScreen:Parts.....................................................................................................72
Figure23:InnerGlass:Parts...............................................................................................................76
Figure24:BackPanel:Parts................................................................................................................80
Figure25:ComponentsforFrontBricksInstallation...........................................................................84
Figure26:ComponentsforTraditionalBricksInstallation..................................................................86
Figure27:On/OffandManualPilotValveSwitches.........................................................................108
Figure28:Valve/ReceiverWiresandInterrupterBlock....................................................................109
Figure29:ORTALRemoteControl....................................................................................................110
Figure30:BurnerComponents.........................................................................................................119
Figure31:BurnerBaseComponents................................................................................................122

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TableofTables
Table1:WallTemperaturesAbovetheFirebox..................................................................................28
Table2:MaterialDamageCausedbyExcessiveHeat.........................................................................28
Table3:RestrictorTable:Burner30–Series40.................................................................................45
Table4:RestrictorTable:Burner45–Series60/75/80......................................................................46
Table5:RestrictorTable:Burner100–Series110/120/130andBurner70–Series90.....................46
Table6:RestrictorTable:Burner135–Series150/170......................................................................47
Table7:RestrictorTable:Burner160–Series200‐250......................................................................47
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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,AGAand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


OrtalInstallationManual 10
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.
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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