Percy Doughty & Co GALLERY CLASSIC 5 User manual

CAST IRON MULTI-FUEL STOVE
V 5.2
Conforms to EN13240:2001
Constructional Requirements
For Intermittent Use
Not to be used in a shared flue
GALLERY CLASSIC 5
INSTALLATION AND OPERATING INSTRUCTIONS
This stove operates at very high temperatures. All persons including children and the
infirm should be warned of this and not be allowed to touch any surfaces whilst in use.
The operator must use the tools provided. The mitten provided is a tool.
APPROVED
REV: D JAN/2013

2
PARTS LIST
17
Output Output kW
Firefox 5
Cycle
Hours
Anthracite 4.6 4
Wood Logs (less than 20% moisture) 4.9 1
Coal (E) 4.3 4
Peat (E) 4.7 2
Closed Fire Briquettes 4.6 4
Outputs stated are under ideal test conditions. Variations will occur due to installation, atmospheric condi-
tions and fuel quality.
(E) - estimate calculated
Flue Gas Temp at
Spigot
Flue Gas
Mass Flow
Flue Diam Ventilation
Reqt
Ventilation Reqt
with draught
stabilizer
402OC 3.9 g/s (wood)
9.7 g/s (ancit) 125mm 5 inches None* 1500mm2** 2.33in2
As tested to the requirements of EN13240 for intermittent use.
Percy Doughty & Co.
Imperial Point, Express Trading Estate,
Stone Hill Road
Farnworth, Bolton, BL4 9TN
Telephone [phone] Fax [phone]
email [email protected] web www.percydoughty.co.uk
Essential characteristic Performance
Test fuel Beech Anthracite
Fire Safety Pass Pass
Emission of combustion products, related to 13% O2CO: 0.11 vol%
Dust: 73 mg/m03
NOx: 98 mg/m03
CxHy: 183 mg/m03
CO: 0.17 vol%
Dust: 86 mg/m03
Surface Temperature Pass Pass
Thermal output / Energy efficiency 4.9kW / 79.4% 4.5kW / 67.4%
Release of dangerous substances Pass Pass
* See approved document J for detailed guidance, especially when installing in newer build properties.
** For newer build properties this may need to be higher if the designed permeability of the home is less
than 5 m3/h.m2 .

16
DIMENSIONS
Dims,
mm ABCDEFGWeight Max Fuel Load
Anthra-
cite
Minimum
Flue
Draught
Max
Fuel
Load
Wood
550 420 215 410 360 105 125 70 kg 5.33 kg 12 Pa
0.048 In
Wg
1kg
Dimensions may vary slightly, the manufacturers reserve the right to adjust them without notice.
Key To Dimensions
A—Height
B—Width
C—Centreline of Flue
D—Height To Centre of Rear Flue
E—Depth
F—Rear to Centre of Top Flue
G—Flue Diameter
See back page for flue data,
ventilation requirements and
stove outputs
Flue pipe requirement (minimum) diameter:
125mm (5 inch) nominal diameter
A
B
C
D
E
F
G
3
1FFX008 Flue Collar
2FFX009 Flue Blanking Plate
3,5,6 FFX001 Stove Body (Rear,Right,Left Panel)
4FFX003 Stove Top Panel
7FFX002 Stove Base Panel
8FFX005 Grate Support Plate
9FFX006 Grate
10 FFX007 Stove Baffle Plate
11 FFX012 Side Brick
12 FFX013 Back Brick
13 FFX010 Leg
14,15 FFX004 Stove Door + Front Panel
16 FFX014 Ash Pan
17 FFX011 Fret
18 FFX024 Secondary Air Duct
19 FFX018 Door Glass
20 FFX027 Glass Panel Seal
21 FFX026 Door Seal
22 FFX023 Secondary Air Slide
23,26,30 FFX022 Primary, Secondary + Riddling Knob Set
25 FFX020 Primary Air Slide
27 FFX029 Operating Tool
28 FFX1 Mitten
29 FFX015 Grate Riddling Rod
31 FFX016, Door Handle Assembly
32 FFX019 Door Glass Retaining Tabs
33 FFX028 Hinge Pin
34 - Stove Identification Label (non-replaceable part)
PARTS LIST

4
ASSEMBLY OF STOVE
Remove legs, collar and blanking plate from stove and fit in desired position. The collar
can be fitted top or rear.
The legs can be fitted at front of ash lip or rearward. To make easier for handling on
installation, remove baffle plate, side bricks, back brick and door. Place in a secure
place to avoid damage. Refit after installation.
STOVE INSTALLATION, OPERATING &
MAINTENANCE INSTRUCTIONS
IMPORTANT: THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT
PERSON AND MUST COMPLY WITH NATIONAL BUILDING REGULATIONS AND
LOCAL BY-LAWS. UNLESS THE INSTALLER IS QUALIFIED TO APPROVE
INSTALLATION THEN APPROVAL MUST BE SOUGHT FROM YOUR LOCAL
BUILDING CONTROL DEPARTMENT. THE SUPPLIERS ACCEPT NO
RESPONSIBILITY IF THIS ADVICE IS NOT COMPLIED WITH.
THIS APPLIANCE HAS BEEN EXTENSIVELY TESTED FOR SAFETY AND
EFFICIENCY, DO NOT ATTEMPT TO MODIFY IT. ALWAYS USE GENUINE
REPLACEMENT PARTS AS RECOMMENDED BY YOUR SUPPLIER. FAILURE TO
ADHERE TO THIS ADVICE COULD INVALIDATE YOUR GUARANTEE. WHEN
OPERATING THE STOVE IN A SMOKE CONTROLLED AREA, ONLY BURN
SEASONED WOOD AND APPROPRIATE SEASONED FUELS.
HEALTH AND SAFETY PRECAUTIONS
Special care must be taken when installing the stove such that the requirements of the
Health and Safety at Work Act are met.
Handling
Adequate facilities must be available for loading, unloading and site handling.
Fire Cement
Some types of fire cement are caustic and should not be allowed to come into contact
with the skin. In case of contact wash immediately with plenty of water.
Asbestos
This stove contains no asbestos. If there is a possibility of disturbing any asbestos in
the course of installation then please seek specialist guidance and use appropriate
protective equipment.
Metal Parts
When installing or servicing this stove care should be taken to avoid the possibility of
personal injury.
15
Typical Installation Into Infilled Masonary Fireplaces
Soot Door
Seal with fireproof lagging
Max150mm
Infill
45 deg minimum

14
Typical Installation For Inglenook Fireplaces
Inglenook fireplaces can have very large bore chimneys. Check with
your installer—you may need a stainless steel flexible liner for solid fuel
fitting.
Closure
Plate
Seal
5
INSTALLATION INSTRUCTIONS
All installations must be undertook in accordance with British Standards:
BS EN 15287-1:2007 - design, installation and commissioning of chimneys;
BS 8303 - code of practice for installation of domestic heating and cooking appliances
burning solid mineral fuel.
Check the chimney is in good condition, dry, free from cracks and obstructions. The
diameter of the chimney flue should not be less than 150mm and not more than
230mm. If any of these requirements are not met, the chimney should be lined by a
suitable method.
The chimney height and the position of the chimney terminal should conform to Building
Regulations.
A flue draught of minimum 12 Pascals and a maximum of 15 Pascals water gauge is
required for satisfactory appliance performance. The flue draught should be checked
under fire at high output and if it exceeds the recommended maximum, a draught
stabiliser must be fitted so that the rate of burning can be controlled, and to prevent
overfiring.
If you have any doubts about the suitability of your chimney, consult your local dealer/
stockist.
The chimney must be swept before connection to the stove and swept every six months
there after. If there is an excessive build up of soot, then the chimney must be swept
and the reason for build up investigated.
An existing fireplace opening can be bricked up or sealed with a register plate, 1.5mm
steel sheet or concrete. A short length of flue pipe no smaller in diameter then the stove
flue outlet or the manufacturer’s stated flue size may then be used to connect the stove
to the chimney. This flue pipe should be of cast iron, 316 grade stainless steel or
vitreous enamelled, nominal thickness 1.2mm. Ensure that the pipe end is no closer
than 76mm to the side or rear chimney walls.
Ideally, the old fireplace should be filled in so that there is a smooth streamlined entry
into the flueway.
If the stove is fitted in place of an open fire then the chimney should be swept one
month after installation to clear any soot falls which may have occurred due to the
difference in combustion between the stove and the open fire.
The length of any horizontal run of the flue pipe must not exceed the flue outlet
diameter on the stove.
It is essential that all connections between the stove and chimney-flue are sealed and
made airtight.

6
Both chimney and flue pipe must be accessible for cleaning and if ALL parts of the chim-
ney cannot be reached through the stove, a soot door must be fitted to enable this this
to be done.
The Primary Air Sealing Plate is located on the front of the grate. To locate in position,
slacken the two screws beneath the grate and pull forward, then close the door fully,
open door and tighten screws.
POSITIONING OF APPLIANCE
The stove can be recessed in a suitable sized fireplace but a permanent free air gap of
at least 100mm must be left around the sides and top to obtain maximum heat output
and for access to the rear of the stove. There should not be any combustible material
within a distance of 600mm from any surface of the stove. Furniture and general soft
furnishings should not be within 900mm of any of the stove surfaces including the stove
pipe. In all instances the stove should be positioned on a non-combustible hearth. Allow
an apron of at least 300mm at the front of the stove and 150mm on either side. The
hearth on which the stove is to be placed should not be less than 125mm thick if the
floor is made of combustible material, and care should be taken to level the stove and
secure the hearth. If existing floors do not have adequate load bearing capacity then
suitable modifications to load bearing plates must be adopted.
When the stove is desired position mark hearth through holes in feet, remove stove drill
and plug hearth for securing stove and levelling. See typical flue connection methods
illustrated.
Upon completion of installation, the appliance should be checked under fire for sound-
ness of joints and seals, and also that all smoke and fumes are taken from the appli-
ance, up the chimney and emitted safely.
Care should be taken that all flues, hearths, and combustion air supplies are in accord-
ance with the current Building Regulations, Local Authority By-laws, British Standards
and Codes of Practice—the Firefox 5 has no ventilation requirement but the Firefox 8
should have a minimum 2145mm2 or 3.22in2 of permanent air entry opening or open-
ings. Care should be taken that these openings can not become obstructed. Considera-
tions and provisions must be made for any other appliances requiring ventilation. An
extractor fan must not be used in the same location as the appliance.
This appliance is not to be used with a shared chimney.
COMMISSIONING OF APPLIANCE
On completion of the installation and commissioning ensure that the operating
instructions for the stove are left with the customer. Ensure to advise the customer on
the correct use of the appliance and warn them to use only the recommended fuel for
the stove. Advise the user what to do should smoke or fumes be emitted from the
stove. The customer should be warned to use a fireguard to BS 8423:2002 in the
presence of children, aged and/or infirm persons.
13
INSTALLATION DIAGRAMS
Typical Top Flue Installation using steel closure plate incorporating
clean out door for chimney sweeping
Seal with
fireproof
Max
150mm
Infill
Typical Rear Flue Installation with clean out door

12
TROUBLESHOOTING
1) Poor heat output
A) Stove too small for a room.
Seek advise from a Qualified Heating Engineer as to (KW) output required for room
size as a guideline the volume of the room in cubic feet divided by 500 i.e. room
15’x15’x8’ would require 3.6kw approx.
B) Chimney and/or flue pipe restricted, room ventilation restricted.
On installation these will have been checked but regular maintenance is necessary
as conditions can change i.e. soot build up, birds nesting, masonry fall, dust build up
or furniture blocking vents.
C) Poor quality fuel.
Only burn dry seasoned timber, soft woods have a lower heat output then hard
woods per hour. Solid fuels vary in heat value check with your coal merchant as to
suitability.
2) Dirty Glass Panel
A) Generally caused by poor fuel quality, see (1c)
B) Use secondary air slide (Airwash) for glass panel
C) Fire burning to low, open air vents on stove create hot fire this may ‘burn’ glass
clean.
D) If glass requires cleaning use glass cleaner recommended by your supplier, only
use glass cleaner or cold glass. DO NOT USE any abrazifs or scrapers these will
scratch glass causing tar build up harder to remove.
3) Unburnt Fuel In Firebox
Insufficient air reaching fuel. Open primary air slide, this will supply combustion air to
burn fuel fully (unless it has reached a ‘point of return’)
Check ash pan is full, empty if required, grate may be blocked de-ash with riddler,
check for jammed clinker or nails in grate when fires out and cold.
4) Smoke And Fumes Entering Room
These are very dangerous and must NOT be tolerated. Open window and allow fire to
burn out, seek expert advice immediately. DO NOT USE stove until the problem is
solved. A list of Qualified Engineers is available from
UK Solid Fuel Association
7 Swanwick Court, Alfreton
Derbyshire DE557AS
Tel- 0845-601-4406
R.o.I.
Irish National Fireplace Organisation
162 Chapel Street, Dublin
Tel-01-801-5959
5) Chimney Fire
Identified by loud roaring sounds, dense smoke and sparks exiting chimney. Shut
down air supply to stove by closing air vents, close stove door fully, call fire brigade
immediately. Regular chimney maintenance will prevent chimney fires. Seek advice
from a Qualified Chimney Sweep. Chimneys must be checked annually more often
when bitumas coal and poor quality smoky fuels are used.
7
CO ALARMS
Building regulations require that whenever a new or replacement fixed solid fuel or wood/biomass
appliance is installed in a dwelling a carbon monoxide alarm must be fitted in the same room as
the appliance. Further guidance on the installation of the
carbon monoxide alarm is available in BS EN 50292:2002 and from the alarm
manufacturer’s instructions. Provision of an alarm must not be considered a substitute for either
installing the appliance correctly or ensuring regular servicing and
maintenance of the appliance and chimney system.
OPERATING INSTRUCTIONS
Primary Air
Primary air is controlled via the sliding vents in the bottom of the door; this provides a convention-
al air draught to the bed of the fire. (+) indicates more air, (-) indicates less air. To adjust, slightly
turn the knob anti-clockwise to loosen, then move sideways. When in the desired position, turn the
knob clockwise until tight.
Secondary Air
Secondary air is controlled via the sliding vent above the door, it is this ‘airwash’ that keeps a
clean and uninterrupted view of the fire, also aiding in good secondary combustion of fuel and
reducing emissions into the chimney and environment. To adjust the secondary air intake, simply
move the slider left (-) for less air or right (+) for more air.
The stove has a pre-determined amount of fixed air supply on the primary and secondary air slid-
ers. This is factory set and should not be adjusted or altered as it
facilitates the clean burn function. Because of the pre-set air supply it is important that the flue
draught requirements are adhered to, i.e. minimum = 12 pascals, maximum = 15 pascals. If the
flue draught exceeds the maximum requirements then over firing can occur and suitable
measures to control draught must be adopted.
Note: Over firing due to fixed air supply will not be dangerously high but efficiency may be com-
promised.
Damper Assembly (optional)
When burning wood only, a flue damper assembly may be fitted. When the damper is set in the
open position the chimney draws at full draught, increasing the volume of air flow through the
stove and flue. Shutting the damper restricts the flow, slowing the rate of burning. This is an after
market product and will be of the type with positive open and closed indication to prevent misun-
derstanding.
De-Ashing
It is important that the riddler is used to remove the ash to ensure an airflow through the firebed
and allow the fire to burn over the entire area of the grate. Insert peg on operating tool into hole in
riddling rod, draw tool forwards and backwards with a slow positive action. Set rod in back position
after de-ashing.
Notes On Wood Burning
Wood burns best on a bed of ash and it is therefore only necessary to remove surplus ash from
the grate occasionally. Burn only dry, well seasoned wood, which should have been cut , split and
stacked for at least 12 months, with free air movement around the sides of the stack to enable it to
dry out. Burning wet or unseasoned wood will create tar deposits in the stove and chimney and
will not produce a satisfactory heat output.

8
The clean burn function will be compromised if: the maximum fuel load is exceeded;
the fuel is not dry/seasoned correctly; the fuel is contaminated i.e. paint, tar resins; or if
the flue draught is insufficient. Maximum fuel load is 1kg. Maximum log length is
240mm. Maximum log diameter is 100mm. When refuelling on to a low firebed and
there is insufficient burning material to light a new fuel charge, excessive smoke
emission can occur. Refuelling must be carried out onto a sufficient quantity of glowing
embers and ash that the new fuel charge will ignite in a reasonable period. If there are
too few embers in the fire bed, add suitable kindling to prevent excessive smoke.
Recommended Fuels
Seasoned wood—moisture content less than 20%
Please note that when refuelling with solid fuel do not pile fuel higher than 30 degrees
from the front bar rearwards—overfuelling can produce temperatures beyond the de-
signed rating of the appliance, causing damage to internal parts.
Lighting The Stove
We recommend that you have two or three small fires before you operate your stove to
its maximum heat output. This is to allow the paint to cure and castings to relax and
consolidate location we recommend ‘running in’ procedure after long shutdowns to pre-
serve life of stove. During this you may notice an unpleasant smell. It is not toxic, but
for your comfort we would suggest that during this period you leave all doors and win-
dows open.
First, load the fire with starting fuel i.e. paper, dry kindling timber and/or fire lighters in
the mode chosen, either wood or coal.
Light the fire at base leaving all air controls open. Allow the fuel to reach a steady glow
and build the fire up gradually. Once you have a good fire established across the grate
bed, further fuel can be added as required.
When your fuel is well alight you can start to restrict the primary air intake. If you are
burning only wood, the primary air control can be fully closed. If you are burning solid
fuel you will require more primary air. Your stove is burning with maximum efficiency
when a bright fire is achieved using minimum air inlet.
The stove can be banked up for long periods. When burning solid fuel empty the ash-
pan. Open air controls and let the fire burn brightly for a short period. Refuel and close
air controls, the exact setting required will depend on the fuel used and the chimney
draw so some practice may be necessary. To revive the fire, open air controls until the
fire is burning brightly, de-ash if necessary (solid fuel only) and refuel. Set air controls
as required.
This appliance is designed to be operated with the door closed. Except for refuelling,
not only is it unsafe to operate with the door open but the appliance efficiency will be
reduced dramatically.
11
Glass Panels
Clean the glass panels when cool with a proprietary glass cleaner. Highly abrasive
substances should be avoided as these can scratch the glass and make subsequent
cleaning more difficult. Wet logs on heated glass, a badly aimed poker or heavy slam-
ming of the doors could crack the glass panels. The glass will not fracture from heat.
Chimney
Check your chimney each year before starting to use your stove for the winter. Birds
may have nested in the chimney or the masonry may have cracked. Both chimney
and flue pipe must be swept at least once a year.
To avoid a build up of soot on the baffle (the plate inside the stove above the grate)
this must be removed and cleaned periodically. This plate locates the back and side
firebricks so note its position before removal. To remove, lift plate and remove one
side brick, this will allow plate to drop and aid removal. To replace, position baffle
plate on back and side brick, lift plate and replace remaining brick, make sure it has
located in position. This must be done when the stove is cold.
For efficient burning of your appliance, make sure the grate is clear of burnt debris i.e.
nails etc.
Where the chimney is believed to have served an open fire installation it is possible
that the higher flue gas temperature from a closed appliance may loosen deposits
that were previously firmly adhered, with the consequent risk of flue blockage. It is
therefore recommended that the chimney be swept a second time within a month of
regular use after installation.
IMPORTANT
-Fuel overloading
The maximum amount of fuel specified in this manual should not be exceeded,
overloading can cause excess smoke.
-Operation with door left open
Operation with the door open can cause excess smoke. The appliance must not be
operated with the appliance door left open except as directed in the instructions.
-Dampers left open
Operation with the air controls or appliance dampers open can cause excess
smoke. The appliance must not be operated with air controls, appliance dampers or
door left open except as directed in the instructions.

10
SEASONAL MAINTENANCE
If the appliance is not to be used for any length of time, e.g. summer months, then it is
recommended that the appliance is cleaned out thoroughly. Air slides should be lightly
oiled and left partially open to allow circulation of air. Regular monitoring of internals
will highlight condensation problems or water ingress. If these problems occur then the
appliance needs drying and the cause of the problem investigating. It is advisable that
after a seasonal shutdown the appliance is re-cleaned. Remove baffle plate, brick lin-
ings, check operation of grate, check flue for any possible blockages. It is advisable to
have the chimney swept at least once or even twice per year. If the appliance is in
constant use, the use of bitumas coal or poor quality wood makes flues soot and tar
up more frequently.
Basic maintenance can be carried out by the appliance operator, i.e removal of baffle
plate, bricks, grate, glass replacement and must be done when the appliance is cold.
Any structural repairs, i.e. panel collar replacement or stove pipe must be carried out
by a suitably qualified engineer.
GENERAL MAINTENANCE
Baffle Plate
This should be removed at least once a month to prevent any build up of soot or fly
ash which could lead to blocked flueways and dangerous fume emission. If the baffle
plate is removed the chimney/flueway can be swept through the appliance.
Baffle Plate Removal and Replacement
Note position before removal. To remove baffle plate, lift up and remove one side brick
left or right. The baffle plate can now be manipulated out of the stove door opening.
Remove the remaining back and side brick—as the bricks are free-standing no dam-
age can now occur due to bricks falling over.
To replace, place rear brick in position and one side brick. Manipulate baffle into posi-
tion and fit remaining side brick. Make sure all parts are located.
Grate Removal
The stove has a single rotating grate operated by an attached riddling rod. To remove,
unscrew control knob and rotate grate out of its guide hole. The centre grate can now
be removed. To replace grate, reverse this procedure. Note position of grate riddling
rod as it connects to grate. The hook on the end of the rod passes under and up
through the arm hole on the grate. If the removal of the outer grate is required then the
baffle plate, rear and side bricks will require removal. The outer grate will then lift out
off it’s stops.
Stove Body
The stove is finished with a heat-resistant paint and this can be cleaned with a soft
brush. Do not clean whilst the stove is hot, wait until it has cooled down. The finish can
be renovated with a suitable brand of paint.
9
Solid Fuels
We recommend the majority of approved manufactured smokeless fuels. Household
coal, which is ‘Smokey’ fuel, can also be used but note that different types will give
different performances. Use as an incinerator is not recommended as fumes from
plastics etc will cause pollution to the atmosphere and will damage stoves internals.
PETROLEUM COKE FUELS OR HOUSEHOLD WASTE SHOULD NOT BE BURNT
ON THIS APPLIANCE
Should any difficulties arise over fuel quality or suitability, consult your local supplier or
the Solid Fuel Advisory Service.
Safety Notes For Your Guidance
FIRES CAN BE DANGEROUS –Always use a fire guard to BS 8423:2002 specification
in the presence of children, the elderly or the infirm. Inform all persons the dangers of
high temperatures during operation of appliance including the stove pipe use
operating tools provided. Do not use an aerosol spray near the appliance under fire.
DO NOT OVER FIRE—it is possible to fire the stove beyond its design capacity, this
could damage the stove, so watch for signs of over firing—if any part of the stove
starts to glow red, the fire is in an over fire situation, and the controls should be
adjusted accordingly. Never leave the stove unattended for long periods without
adjusting the controls to a safe setting—careful air supply control should be exercised
at all times.
Warning Note
Properly installed, operated and maintained this stove will not emit fumes into the
dwelling. Occasional fumes from de-ashing and re-fuelling may occur. However,
persistent fume emission is potentially dangerous and must not be tolerated. If fume
emission does persist, then the following immediate action should be taken:
(a) Open doors and windows to ventilate the room and then leave the premises.
(b) Let the fire go out.
(c) Check for flue or chimney blockage and clean if required
(d) Do not attempt to relight the fire until the cause of the fume emission has been
identified and corrected. If necessary seek expert advice.
The most common cause of fume emission is flueway or chimney blockage. For your
own safety these must be kept clean at all times.
Your installer should have fitted a CO alarm in the same room as the appliance. If the
alarm sounds unexpectedly, follow the instructions given under “Warning Note” above.
DO NOT FIT AN EXTRACTOR FAN IN THE SAME ROOM AS THIS APPLIANCE