Real Fires 800 User manual

Real Fires Minimal Range installation instructions
Model 800
INSTALLATION INTO TIMBER FRAMING
AND NEW MASONRY BLOCK CONSTRUCTION
New Masonry Block The following instructions are for installation into timber frame.
The method of installation is the same for New Masonry Block.
See Masonry Block Drawing
Ventilation
Ventilation to the room that houses the fire must meet the requirements of NZ5261
Framing Details
Prior to installation, timber framing needs to be provided to suit the selected Real
Fire. See installation drawing
Hearth
A non combustible Hearth must be provided in front of the Real Fire unless the
flooring in front of the fire is non combustible. The minimum size is 300mm out from
the fire and 150mm each side wider than the fire.
Height of fire from floor
It is important to confirm the height the fire is to be installed from the floor level. This
is usually the hearth height. For example if the hearth is 100mm high then the fire
needs to be installed 100mm high. ( note- some elevated installations specify the fire
higher than the hearth). Once the height is confirmed a platform needs to be built to
support the firebox. The platform can be of timber construction. It needs to be sturdy
and level.
Gas Supply
A suitable gas supply needs to be provided at the right hand rear corner of the timber
frame cavity. The pipe sizing should be calculated to supply gas to suit the megajoule
rating of the fire. See rating chart. The gas supply should be reduced down to 10mm
copper pipe at the fireplace location and left with a coil of approx 1 metre to feed into
the firebox.
Gas Rate Chart
800 40 MJ/h 40 MJ/h
1000 51 MJ/h 51 MJ/h
1200 64 MJ/h 59 MJ/h
LPG
Natural Gas
Minimal Model

Electrical supply
An electrical supply will be required. This should be by means of an isolating wall
switch provided by an electrician, located preferably at the left side of the fireplace.
Not inside the framing cavity. See installation drawing for preferred location of
switch.
Insulation Kit & Timber Clearance
When installed into timber framing the Real Fire must be installed with an insulation
kit. This must be ordered with the fire and fitted in the factory by Real Fires.
The insulation kit allows the firebox to be installed with minimal timber clearances:
10mm clearance on sides of firebox, 25mm clearance from rear and top of firebox
The timber clearance from the twin wall flue is also 25mm.There is no requirement
for any additional fireproof materials within the fireplace cavity providing minimum
clearances are allowed.
Recessed firebox installation
Standard wall linings are not suitable for recessed installation. Please contact
Real Fires for advice prior to installation
Flue requirements
The minimum flue height is 2.4 metres
The flue cowl should be no lower than 900mm vertically from the roof line and a
2 metre horizontal clearance from any part of the building. see cowl clearance
drawing
Flue and Cowl Size
Real Fire Minimal 800 200mm inner flue/ 250mm outer flue 200/250 Cowl
Real Fire Minimal1000 200mm inner flue/ 250mm outer flue 200/250 Cowl
Real Fire Minimal 1200 250mm inner flue/ 300mm outer flue 250/300 Cowl
Installation instructions
Firstly the firebox and flue are installed and then the burner is installed. The burner
may be installed at a later date when all the construction work is complete and the
hearth is in place.
The firebox is placed on the platform provided and the gas pipe is pushed through the
hole at the right hand rear of the firebox ( RH from the front of the fire).
This pipe is to be connected to the burner but may be left sealed if the burner is to be
installed later. Leave enough pipe to connect the burner.
Once the firebox is in place ensure it is level. Usually the firebox is positioned
centrally and so that the flange around the firebox opening is left forward of the
timber framing by 10mm, this is to allow for giboard to be fixed behind the flange.
From the positioned firebox the flue can be assembled. The flue is in 1200mm lengths
with both inner and outer flue. Each flue length has a crimped end to join tightly to
the next length. Each joint must be securely fixed by at least three stainless steel
rivets. The firebox has a spigot for the flue to locate over.
The flue lengths should be installed with the crimped end facing up.

The Firebox and flue should be secured by fixing with seismic strapping and/or
brackets to framing.
Flue bends are available from Real Fires if the flue needs to be offset.
Appropriate weatherproof roof flashing/ chimney capping must be used to comply
with NZS 5261
Once the installation of the firebox and flue is complete, the building work around the
fireplace can continue. A timber cross frame is usually fixed above the firebox for gib
fixing. This must be at least 25mm from the firebox.
The firebox has an electrical cable from the rear left hand side. The cable is
approximately 1.2 metre long, it is intended to be connected by an electrician to an
isolating switch positioned facing the room preferably on the left hand side of the
fireplace cavity. See diagram---
(Please ensure the cable is not left behind the firebox and overlooked. It is difficult to
gain access once the giboard is fixed)
Timber surround
If a timber surround is to be fitted, ensure it complies with Real Fires minimum
clearance dimensions. See installation drawing
Installation of Real Fires burner into firebox
The electronic controlled burner is supplied assembled and boxed complete with,
reflectors, front panel vermiculite, logs, & coals.
To make the gas connection, place the burner in the firebox with the bottom tray
fitting into the cut outs in the bottom of the firebox and it is positioned central. The
gas pipe should be bent into position & marked for cutting. Remove the burner, cut
the pipe and make a flare connection.
Replace the burner into the firebox.
Plug in electrical connectors
Line in 3 pin socket connects to 3 pin plug to control box
4 pin socket from control box connects to 4 pin plug to fan
The lead with small jack plug connects to the remote control receiver board on the
back of the front fascia. The fascia panel will need to be left off until the fire has been
connected and tested.
Connect the gas pipe. Test for soundness.
Natural Gas Burner
Fill the burner tray with the vermiculite supplied ensuring the burner tube is
completely covered.
Lay logs and coals on top of the vermiculite as shown in the Log/Coal layout
drawing. Note that the shelf at the back of the burner is also used. Do not place logs
or coals close to the pilot. It important that the coals are not too tightly placed as
this will affect the heat output. The flame picture and radiant glow is better when
there is good spacing between the coals.

L.P.G. Burner
The L.P.G. burner is a flat steel burner. This burner is supplied with a bag of coarse
vermiculite, spread this thinly (5 to 10mm) over the surface of the burner.
Follow instructions for coal placement as with Natural Gas burner.
Commissioning of the Burner
The mains power supply needs to be connected and turned on. See instructions for
remote control. Press the power on at the remote. The pilot should ignite, it may take
several attempts until air has been purged out and gas is through. Once the pilot has
ignited the burner will light. Check that the flame travels easily across the burner and
that coal placement does not affect ignition. Re- position coals if required.
Ensure that there is no vermiculite touching the Pilot, ignition electrode, or flame
sense electrode. This will cause ignition failure.
Burner Gas pressure
Check burner gas pressure from the test point on the burner supply pipe on the
Natural gas model and on the injector elbow on the L.P.G. model.
See appliance data badge for pressure settings.
Adjustment of the Burner Gas pressure
Adjust the pressure at the gas valve if required. See valve picture
There are two adjustments, High and low setting. These are located at the front of the
valve at the head of the blue solenoid.
High adjustment – This is the outer Brass hexagonal nut
Low Adjustment - This is the inner Red adjustment screw
When adjusting the high setting hold the low adjuster in place otherwise both may
turn.
Fit the front fascia panel
Fit front fascia panel correctly onto fixing screws
Fit side reflectors
Fit side reflectors by tilting on an angle locating base onto fascia panel and then
placing vertical. The return on the reflector then hooks over a securing screw in the
side of the firebox.

Fitting Trim to Firebox
Fit the trim to the firebox. The trim brackets are designed to hang over the flange on
the front of the firebox. The flange has provision to be moved slightly in or out to
allow the bracket to fit. The flange on each side of the firebox has a raised square near
the base of the fire. The Velcro pad is fixed to this, by removing the backing from one
side of the pad and pushing firmly in place. Then remove backing from other side.
Repeat on opposite side. Hang trim on brackets and check for level then push firmly
onto Velcro pad.
Check that the fire is operating correctly and test for spillage of products of
combustion.
Instruct user
Once the installation is complete, instruct the user on the operation of the fire and
complete commissioning details in Real Fires user manual.
All installations must be Certified

This drawing is a typical example of the log and coal layout on a Real Fire 800
The layout is basically the same for all models with logs and coals decreased or increased in width
to suit the size of fi re. (The pilot ignition assembly has been omitted from the drawing).
It is important to ensure that the logs and coals are not too tightly placed as this will affect heat
output. Do not place Logs and Coals close to the pilot and ensure that the burner lights easily and
fl ame travels easily across the burner. Reposition if required.
fl ame travels easily across the burner. Reposition if required.
Real Fires Log and Coal Layout

Real Fires Minimal Range
Model 800
INSTALLATION INTO EXISTING MASONRY FIREPLACE
Ventilation
Ventilation to the room that houses the fire must meet the requirements of NZS 5261
Fireplace cavity and chimney inspection.
Real Fires are designed for installation into an existing masonry fireplace and
chimney.
Prior to installation the fireplace should be measured and a suitable size Real Fire
selected. In most situations the fireplace will require masonry alteration to
accommodate the firebox. See installation drawing
The chimney will need to be inspected for suitability and checked for draw. Ensure it
complies with a minimum height of 2.4 Metres. The top of the chimney is a minimum
vertical clearance of 900mm from the roofline and 2 Metre horizontal clearance from
any roofline or any other part of the building. See cowl clearance diagram
The chimney should be swept prior to installation.
New Masonry Block Chimney
Installation of a Real Fire into a new masonry chimney may require installation with
an insulation kit and flue kit. This will involve leaving the fireplace opening 1200mm
high to allow installation. The method of installation is as per timber frame
installations. Please consult Real Fires in this situation for advice prior to
installation.
Hearth
A non combustible Hearth must be provided in front of the Real Fire unless the
flooring in front of the fire is non combustible. The minimum size is 300mm out from
the fire and 150mm each side wider than the fire.
Height of fire from floor
It is important to confirm the height the fire is going to be installed above the floor.
This is usually the hearth height. For example if the hearth is going to be 100mm high
then the base of the fireplace cavity usually needs to be the same height. ( note- some
elevated installations specify the fire higher than the hearth ).
It is important that the base of the cavity is plastered smooth and level.
Gas supply
A suitable gas supply needs to be provided at the right hand rear corner of the
fireplace cavity. The pipe sizing should be calculated to supply gas to suit the
megajoule rating of the fire. See rating chart. The gas supply should be reduced down
to 10mm copper pipe at the fireplace location and left with a 10mm coil of approx
1metre to feed into the firebox.

Gas Rate Chart
Electrical supply
An electrical supply will be required. This should be by means of an isolating wall
switch provided by an electrician and located near the fireplace. Not inside the
fireplace cavity.
Recommendation
Performance of the fire will be improved if the fireplace cavity is lined with an
insulating fire rated product such as Rockwool.
Cowl Requirements
800mm Fire 200mm Cowl
1000mm Fire 200mm Cowl
1200mm Fire 250mm Cowl
Installation instructions- Firebox
Once the fireplace cavity has been prepared and the gas supply pipe is positioned at
the rear right hand side. The firebox can be installed. See installation drawing.
Note- Electrical wiring
The firebox has an electrical lead from the rear left hand side. The lead is
approximately 1.2 metre long, it is intended to be connected by an electrician to an
isolating wall switch near the fireplace.
The lead will need to be left accessible after the firebox is installed. This will mean
drilling through the masonry cavity base, side, or rear as appropriate. Feed the lead
through as the firebox is positioned into the masonry cavity.
The lead must be positioned low and not touching the back of the firebox.
Installation instructions- Firebox continued
As the fire is positioned into the masonry cavity, the 10mm copper gas pipe is pushed
through the hole at the right hand rear of the firebox (RH from the front of the fire)
This pipe is to be connected to the burner after firebox installation.
Apply high temperature sealant to the back of the flange around the front of the
firebox. Push the firebox into position carefully and ensure a good seal is made
between the flange and the masonry. If required the firebox can be secured in place by
drilling the flange and securing to the masonry with screws.
800 40 MJ/h 40 MJ/h
1000 51 MJ/h 51 MJ/h
1200 64 MJ/h 59 MJ/h
LPG
Natural Gas
Minimal Model

Installation instructions- Cowl
A cowl spigot plate is fixed to the chimney by masonry screws and mortar.
The cowl is then pushed firmly onto the spigot.
Installation instructions- Burner into firebox
The electronic controlled burner is supplied assembled and boxed complete with
reflectors, front panel, vermiculite, logs, & coals.
To make the gas connection, place the burner in the firebox with the bottom tray
fitting into the cut outs in the bottom of the firebox and it is positioned central. The
gas pipe should be bent into position and marked for cutting. Remove the burner, cut
the pipe and make a flare connection.
Replace the burner into the firebox.
Plug in electrical connectors
Line in 3 pin socket connects to 3 pin plug to control box.
4 pin socket from control box connects to 4 pin plug to fan
The lead with the small jack plug connects to the remote control receiver board on the
back of the stainless steel fascia panel. The fascia panel will need to left off until the
fire has been connected and tested.
Connect the gas pipe. Test for soundness.
Natural Gas burner
Fill the burner tray with the vermiculite supplied ensuring the burner tube is
completely covered.
Lay logs and coals on top of the vermiculite as shown in the Log/Coal layout
drawing. Note that the shelf at the back of the burner is also used. Do not place coals
or logs close to the pilot.
It is important that the coals are not too tightly placed as this will affect heat output.
The flame picture and radiant glow is better when there is good spacing between the
coals, as in the pictures.
L.P.G. Burner
The L.P.G. burner is a flat steel burner. This burner is supplied with a bag of coarse
vermiculite, spread this thinly (5 to 10mm) over the surface of the burner.
Follow instructions for coal placement as with Natural Gas burner.
Commissioning of the burner
The mains power supply needs to be connected and turned on. See instructions for
remote control. Press the power on at the remote. The pilot should ignite, it may take
several attempts until the air has been purged out and gas is through. Once the pilot

has ignited the burner will light. Check that the flame travels easily across the burner
and that coal placement does not affect ignition. Re- position coals if required.
Ensure that there is no vermiculite touching the pilot, ignition electrode, or flame
sense electrode. This will cause ignition failure.
Burner Gas pressure
Check burner gas pressure from the test point.
The Natural Gas Test Point is located on the burner supply pipework.
The L.P.G. Test point is located on the burner injector elbow.
See appliance data badge for pressure settings
Adjustment of the Burner Gas pressure
Adjust the pressure at the gas valve if required. See valve picture
There are two adjustments, High and Low setting. These are located at the front of the
valve at the head of the blue solenoid.
High adjustment- This is the outer Brass hexagonal nut
Low adjustment – This is the inner Red adjustment screw
When adjusting the high setting hold the low adjuster in place otherwise both may
turn.
Fit the front fascia panel
Fit front fascia panel correctly onto fixing screws
Fit side reflectors
Fit side reflectors by tilting on an angle locating base onto fascia panel and then
placing vertical. The return on the reflector then hooks over a securing screw in the
side of the firebox.
Fitting Trim to Firebox
Fit the Stainless Steel trim to the firebox. The trim brackets are designed to hang over
the flange at the front of the firebox. The flange has provision to be moved slightly to
allow the bracket to fit. The flange on each side of firebox has a raised square near the
base of the fire. The Velcro pad is fixed to this, by removing the backing from one
side of the pad and pushing firmly in place. Then remove backing from the other side.
Repeat on the opposite side. Hang trim on brackets and check for level then push
firmly onto Velcro pad.
Check that the fire is operating correctly and test for spillage of products of
combustion.
Instruct User
Once the installation is complete, instruct the user on the operation of the fire and
complete commissioning details in the Real Fires user manual.
All installations must be certified

This drawing is a typical example of the log and coal layout on a Real Fire 800
The layout is basically the same for all models with logs and coals decreased or increased in width
to suit the size of fi re. (The pilot ignition assembly has been omitted from the drawing).
It is important to ensure that the logs and coals are not too tightly placed as this will affect heat
output. Do not place Logs and Coals close to the pilot and ensure that the burner lights easily and
fl ame travels easily across the burner. Reposition if required.
fl ame travels easily across the burner. Reposition if required.
Real Fires Log and Coal Layout