RealFlame DOUBLE VISION Installation instructions

DOUBLE VISION®
DECORATIVE FIREBOX
INSTALLATION & OPERATING MANUAL
The Double Vision gas firebox is approved to be installed as a zero
clearance firebox and is designed to operate on Natural Gas and
Propane (LPG) gases ONLY. Approval Number 6731.
VERSION 13

2
WARRANTY
Provided your Real Flame gas fire is installed in strict accordance with our installation instructions, the
firebox is unconditionally guaranteed for ten years and all other parts for twelve months from date of
purchase.
This unconditional warranty covers parts and labour at our discretion taking into consideration normal wear
and tear and does not cover fires installed in outdoor settings.
INSTALLATION NOTICE
The installation of this appliance is only to be carried out by an authorised person in accordance
with the Manufacturer’s Instructions, local gas fitting regulations, AG601 installation code for gas
burning appliances and any other relevant statutory regulations.
In all cases the installation of this appliance shall meet the requirements as set out in AS5601/AG601.
NOTE: A slight smell may be apparent for the first few hours of use. This is due to the heat resistant
paint curing. It is recommended to open windows in the room for the first lighting of the fire. In some
instances a slight discolouration may occur inside the firebox. This is a normal condition and is not
covered by warranty.
NOTE: The Double Vision Modular fire is primarily a decorative appliance and is not certified as
a space heater.
IMPORTANT SAFETY NOTICE
DO NOT PLACE ARTICLES ON OR AGAINST THIS APPLIANCE.
DO NOT USE OR STORE FLAMMABLE MATERIAL NEAR THE APPLIANCE.
DO NOT SPRAY AEROSOLS IN THE VICINITY OF THIS APPLIANCE WHILST IT IS IN OPERATION.
CARE MUST BE TAKEN TO ENSURE THAT ANY RETURN AIR REGISTER OR EXHAUST SYSTEM
DOES NOT ADVERSLEY AFFECT THE OPERATION OF THE APPLIANCE OR DRAUGHT OF
CHIMNEY OR FLUE.
VENTILATION REQUIREMENTS
MODEL SIZE EFFECTIVE VENTILATION
Double Vision 850 40,000 sq mm
WARNING
This firebox has a naked flame, care should be taken when it is operating if children or the infirm are
in close proximity. A safety screen is recommended if constant supervision is not possible.

CONTENTS
Contents ..................................................................................................................3
Data Plate.................................................................................................................4
Firebox dimensions..................................................................................................5
Dimensions ..............................................................................................................6
Zero Clearance Timber Frame Installation ..............................................................7
Inbuilt Installation Procedure ...................................................................................8
Lighting pilot and main burner.................................................................................9
Tests to be carried out by installer .........................................................................10
Failure procedure...................................................................................................10
Maintenance...........................................................................................................11
Troubleshooting the Millivolt Gas System Control ................................................12
Service - Igniter and Burner ...................................................................................13
Parts Kit, Gas Control Assembly, Burner Assembly ..............................................14
Flue requirements ..................................................................................................15
Optional Power Flue...............................................................................................16
Introduction.............................................................................................17
Installation...............................................................................................17
Motor Clearance .....................................................................................19
Frameout.................................................................................................20
Motor exloded view ................................................................................20
Internal Motor..........................................................................................21
External Motor ........................................................................................22
Wiring Diagram.......................................................................................23
Parts List .................................................................................................23
Troubleshooting Electronic Ignition and Power Flue System ...............................24
Real Flame contact information .............................................................................28
3

MODEL SIZE N.G LPG NG LPG NG LPG
DOUBLE VISION 850 2.8mm 1.35mm 52 49 0.87kPa 2.64kPa 6731 540 Double
INJECTOR Mj/Hr TPP APPROVAL No. BURNER
MODEL
4
DATA PLATE (Affixed to the base of the unit for reference to gas pressure & consumption)

380mm
950mm
155mm
600mm
850mm
50mm
50mm
50mm
950mm
850mm
210mm
230mm
300mm
160mm
470mm
FLUE
Inner 225mm
Outer 275mm
COVER PLATE
FOR ELECTRONICS
GAS LINE INLET
DOUBLE VISION FIREBOX
• The Double Vision is designed to be installed into a new frame out as shown on page 6.
• The fire can be installed at ground level or raised to what ever height is required providing
the flue length is 2.7 meters or more.
• The firebox can sit directly onto a wooden surface.
• The Double Vision requires twin skin flue with an AGA approved cowl
• The control valve on the Double Vision is a millivolt system and as such, no electrical work
is required
5
Overall Dimensions (in mm)
MODEL Inner Outer
850 225mm 275mm

6
FRONT - 4 SIDED FRONT - 3 SIDED
B
A
C
D
DIMENSIONS
Trim
AB CDEF GH
850 950 600 470 272.5 295 210 230
IJKLMNO
420 - 50 50 - 420 380
AB CD
1043 613 513 100

DOUBLE VISION FIREBOX
Double Vision Zero Clearance Timber Frame Installation
Floor 0 mm
Sides 25 mm
Top 100 mm
Flue Outer 25 mm
CLEARANCES FROM
COMBUSTIBLES
Plasterboard to run beyond stud as shown.
If unit requires trim only, frameout remains the same.
NOTE
PLAN
7
Plaster to run
beyond stud and
behind trim A
B
C
D
(Recommended only)
HEATER
TRIM
AB C D
875 1000 600 2100
Frameout Dimensions (in mm)

Check frame out has been constructed correctly and has not been plastered.
Check frame out and structure above is clear of any structures that may impede the flue run.
TICK BOXES
DOUBLE VISION FIREBOX
Double Vision Inbuilt Installation Procedure
• Ensure an adequately sized gas connection is available within the frame out, a 15mm gas
copper pipe is to be provided into the firebox. An access hole is provided in the base of the
firebox. A 500mm tail is required into the firebox to allow for connection to the burner.
• Position the unit ensuring the millivolt loom and gas pipe are accessible.
• Connect the twin skin flue (or Optional Power Flue if supplied).
• Install an AGA approved 225mm gas cowl ensuring the termination meets all relevant code
requirements.
• Place the burner in the double sided firebox.
• Connect the gas line to the burner connection using the 15mm flared copper union
(supplied).
• Connect the two core wiring terminals to the millivolt system as shown below.
Note: The valve is pre wired and completely self contained to generate its own power. DO
NOT connect any external power to it.
Note: Do not locate the switch further than 6 meters from the firebox.
• Screw the four burner legs to the base of the firebox in the holes provided.
• Place the burner surround over the burner.
• Place the coals (or optional pebbles) randomly on the ceramic blanket. If coals and logs
option is supplied, place logs on top of coals randomly.
IMPORTANT! Only ceramics supplied by Real Flame are to be used.
GAS LINE INLET
8

FOR YOUR SAFETY READ BEFORE LIGHTING
The Double Vision has a pilot which must be lit using the piezo ignition. When lighting the pilot
follow the instructions exactly.
Before lighting the pilot, check for gas leaks.
Use only your hand to push in and turn the gas control knob, never use tools. If the knob will not
push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempt to
repair may result in a fire or explosion.
Do not use this appliance if any part has been under water. Immediately call a qualified service
technician to inspect the appliance and replace any part of the control system and any gas control
that has been under water.
Before lighting the pilot make sure that the gas line is connected.
LIGHTING PILOT AND MAIN BURNER
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information.
2. Push in gas control knob and turn to “PILOT”
3. NOTE: Control knob cannot be turned from “OFF” to “PILOT” unless the knob is pushed in
slightly. Do not force.
4. Light pilot burner following steps below.
5. When the control knob is set at pilot, push it all the way in and hold it in. Immediately light the
pilot using the piezo igniter. Red igniter button may need to be pressed rapidly several times.
Once the pilot has lit keep holding the control knob in for about 45 seconds. Release the knob
and it will “pop” back out, the pilot should remain lit. If pilot goes out repeat steps 1 to 5
6. Turn gas control knob to the “ON” position
7. Turn the switch on to ignite the burner. The switch is supplied with the unit and should be
installed within 6m of the fire.
• After lighting the pilot, if the control knob does not “pop” out when released, stop and
immediately call your service technician.
• If the pilot will not stay lit after several tries turn the gas control knob to “OFF” and call your
service technician.
N.B: WHEN THE CONTROL KNOB IS TURNED TO THE “OFF” POSITION IT WILL TAKE
APPROXIMATELY 60 SECONDS FOR THE VALVE TO RELEASE AND ALLOW YOU TO MOVE
THE KNOB. DO NOT FORCE THE KNOB.
TO TURN OFF GAS TO APPLIANCE
A. Turn switch to “OFF” position.
B. Push in gas control knob slightly and turn to the off position.
OFF
Visit www.realflame.com.au
to view a video instruction.
PILOT
ON
9

TESTS TO BE CARRIED OUT BY INSTALLER
1. Carry out a smoke test to ensure the fireplace is drawing.
2. Test that the Test Point Pressures are correctly set. Refer to Data Plate on page 4 for
correct setting.
3. Check that there are no gas leaks form any of the fittings.
4. Explain to the customer how the unit operates and how to turn it on and off.
FAILURE PROCEDURE
1. The pilot is burning.
2. Ensure that the wiring terminals on the control valve are not loose.
3. Test that the inlet and working pressures are both correct.
If when the control knob is turned to the “ON” position and the wall switch is turned to the
“ON” position, the fire fails to ignite, check the following:
VENTURI
INJECTOR
HOLDER
PILOT BURNER TUBE
SIDE VIEW
CC
Model 540 = 270mm
Model 750 = 370mm
Model 540 = 270mm
VENTURI
STEEL MESH
CERAMIC BLANKET
VENTURI
INJECTOR
INJECTOR
HOLDER
CONTROL VALVE
PRESSURE TEST POINT
GAS CONNECTION
FLAME
ADJUSTMENT
FRONT VIEW
10

MAINTENANCE
The appliance should be thoroughly inspected before initial use and at least annually by a
qualified service technician. If any abnormal condition is observed the home owner must contact
a qualified service technician.
IMPORTANT: TURN OFF GAS BEFORE SERVICING THE APPLIANCE.
MAINTENANCE SCHEDULE
Annually (Before Winter Season)
Maintenance Task
Inspection/Cleaning
burner, logs and
controls.
Accomplishing Person
Qualified Service
Technician
Procedure
Inspect valve and ensure that it is operating
correctly. Check piping for leaks. Vacuum the
control compartment, fireplace logs and
burner area.
Check Flame pattern
and flame heights.
Qualified Service
Technician
Ensure that the flame pattern is consistent
and not impinged by the logs.
Inspecting/Cleaning
Pilot and Burner
Qualified Service
Technician
Remove any surface build up on pilot and
burner assembly. Wipe the pilot nozzle,
ignitor/flame rod and hood. Ensure the pilot
flame engulfs the Thermocouple and
Thermopile.
11

TROUBLESHOOTING THE MILLIVOLT GAS SYSTEM CONTROL
IMPORTANT
Valve system troubleshooting should only be carried out by a qualified service technician.
If supply cord is damaged or the unit needs repairing, it shall be repaired by the manufacturer or
its service agent or similarly qualified person in order to avoid a hazard.
Symptom
Spark ignitor will not
light pilot after
repeated triggering
of igniter button
Pilot will not stay lit
after carefully
following the
lighting instruction
Possible Cause
A. Defective ignitor
B. Defective or
misaligned electrode at
pilot (spark at electrode).
C. Gas supply pressure
errant.
D. Pilot orifice plugged.
A. Defective pilot
generator (thermocouple)
Corrective Action
Check for spark at electrode and pilot. If no spark and
electrode wire is properly connected, replace ignitor
Using a match, light the pilot. If pilot lights, turn off pilot and
trigger the igniter button again. If pilot lights, an improper
gas mixture caused the bad lighting and a longer purge
period is recommended. If pilot will not light - check gap at
electrode and pilot - should be 1/8” to have a strong spark.
If gap measures 1/8”, replace pilot.
Check inlet gas pressure. It should be :
• 0.87 kpa for Natural Gas
• 2.64 kpa for L.P.G.
Refer Data information plate.
Clean or replace pilot orifice.
Check pilot flame, it must impinge on thermocouple. Clean
and/or adjust pilot for maximum flame impingement on the
thermocouple. Ensure that the connection between the
valve and the thermocouple is tight and secure.
Pilot burning, no gas
to burner, valve
knob “ON”, Wall
switch “ON”
A. Wall switch or wires
defective.
Check wall switch and wires for proper connections.
Jumper wires across terminals at wall switch, if burner
comes on, replace defective wall switch. If okay, jumper
across wall switch wires at valve, if burner comes on wires
are faulty or connections are bad.
Frequent
pilot/burner outage
A. Pilot flame may be too
low or blowing (High)
causing the pilot/valve
safety to drop out.
Clean and/or adjust pilot flame for maximum flame
impingement on thermocouple.
B. Thermopile may not be
generating sufficient
millivoltage.
Check thermopile with millivolt meter. Take reading at
thermopile terminals of gas valve. Should read 325 millivolts
minimum with optional wall switch “OFF”. Replace faulty
thermopile if reading is below specified minimum.
C. Blocked burner orifice. Check burner orifice for blockage and remove.
12

SERVICE
Igniter
Burner
CC
Model 540 = 270mm
Model 750 = 370mm
Model 540 = 270mm
VENTURI
STEEL MESH
CERAMIC BLANKET
VENTURI
INJECTOR
INJECTOR
HOLDER
CONTROL VALVE
PRESSURE TEST POINT
GAS CONNECTION
FLAME
ADJUSTMENT
THERMO PILE
RED WIRE
WHITE WIRE
THERMO
GENERATOR
TP TH TP TH
HEAT SWITCH
13

GAS CONTROL ASSEMBLY
PART PART No. AGA Approval
SIT 820 NOVA Mv 0820332-NAT GAS 4032
SIT 820 NOVA Mv 0820331-LPG 4032
SIT THERMOCOUPLE 200261 4032
SIT PILOT ASSEMBLY 190610 4032
SIT THERMAL GENERATOR 240002 4032
PIEZO WITH LEAD 28510 4032
PIEZO IGNITOR PUSH BUTTON 73953 4032
PIEZO BRACKET 978099 4032
Thermocouple
Pilot
Power Generator
Valve
Piezo Ignitor
PARTS KIT
Piezo Lead
Control Valve
Pilot Cover
Mesh
Ceramic Logs
Ceramic Fibre Coals
50mm Ceramic Blanket
280mm
90mm
50mm
60mm
200mm
540mm
200mm
1.6mm STEEL
BURNER ASSEMBLY
All spare parts
listed are
available from
the manufacturer.
NOTE:
If pebbles are
used, lay them
randomly on top
of the ceramic
blankets.
14

FLUE REQUIREMENTS
Natural Draught
The standard natural draught flue kit consists of 4 x 900mm lengths of 225/275 twin skin flue
and an AGA approved cowl.
3.6m Flue Kit
complete with cowl
150mm Gas Cowl
Twin Skin Flue
150 x 200mm
Electrical
wiring
between fan
and unit
Power Flue Kit (Optional – refer to pages 16 to 22 for details)
The standard Power Flue Kit consists of ;
• 1 x Power Flue Fan
• 1 x Power Flue Motor
• 1 x Control Module
• 1 x Electronic Ignition Pack
• 1 x Baffle
• 1 x Pressure Differential Switch
• 1 x Loom
• 1 x Termination Cowl (horizontal or vertical)
Fan Casing
Baffled Flue
Twin Skin Flue 150 x 200mm
(Optional for additional height if required.)
15

OPTIONAL POWER FLUE
Introduction - the Power Flue System
POWER FLUE DESIGN
A ‘flue’ using a fan to remove or assist in removing combustion products from an appliance, is
known as a ‘power flue’.
POWER FLUE APPLICATION
A power flue application can be used to enable a client to have a decorative fire with a horizontal
flue run or a vertical flue run where flue space is inadequate for the normal flue.
THE INSTALLATION MANUAL OF THE REAL FLAME POWER FLUE SYSTEM IS TO BE READ IN
CONJUNCTION WITH THE INSTALLATION MANUAL OF THE REAL FLAME PRODUCT BEING
USED. THE DESIGN OF THE REAL FLAME POWER FLUE SYSTEM IS SUBJECT TO COPYRIGHT
AND ALL INFRINGEMENTS WILL BE VIGOROUSLY PURSUED.
VENTILATION REQUIREMENTS
Air supply to the unit is to be in accordance with ventilation Clause 5.4 of the Gas Code 601.
Ventilation requirements do not change by using a power flue.
All Real Flame installation manuals have the ventilation areas clearly defined for each product.
ACCESS TO POWER FLUE MOTOR
Access must be provided to the flue motor, this access MUST be at least 400mm x 400mm.
There MUST be a minimum clearance of 250mm between the top of the motor and any fixed
object i.e. ceiling or stud work. This is so the top of the fan box can be removed.
WIRING OF THE POWER FLUE
All wiring for the power flue is carried out at the factory and plug connectors are fitted for easy
installation. The power supply for the power flue is via a 3-pin plug at the rear of the firebox that
can be plugged into a power socket within the cavity.
ISOLATION SWITCH
If the power point is within a cavity an isolation switch accessible from outside the cavity must be
provided.
WIRING CLEARANCES
Wiring must at all times have a clearance of at least 150mm from the flue.
FAN FAILURE SENSING DEVICE
All Real Flame Power Flue systems are fitted with a sensing device within the unit to ensure that,
in the event of flow failure, the safety shut off valve within the module will go into lockout and shut
off the gas supply to the unit.
‘LOCKOUT’
‘Lockout’ is the term used when the module in the unit senses a fault. When a fault is detected by
the module it will shut off the gas and go into lockout. If this occurs contact the manufacturer.
Installation Instructions
16

OPTIONAL POWER FLUE (continued)
Installation Instructions (continued)
LOCATION OF FLUE TERMINAL FOR POWER FLUE
Listed below are the minimum clearances required for fan-assisted terminations:
1. Below eaves, balconies and other projections. .........................................................200mm
2. From the ground, above a balcony or other surface. ................................................300mm
3. From a return wall or external corner..........................................................................300mm
4. From a Gas meter. ....................................................................................................1000mm
5. From an electricity meter or fuse box.........................................................................500mm
6. From a drainpipe or soil pipe. ......................................................................................75mm
7. Horizontally from any building structure or obstruction facing a terminal.................500mm
8. From any other flue terminal. Cowl, or combustion air intake. ..................................300mm
9. Horizontally from any openable window, door, non-mechanical air inlet,
or any other opening into a building with the exception of sub floor ventilation.......300mm
10. From a mechanical air inlet including a spa blower.................................................1000mm
11. Vertically below an openable window, non-mechanical air inlet,
or any other opening into a building with the exception sub floor ventilation...........500mm
ELECTRICAL
SHOULD THE SUPPLY FLEX AT THE BACK OF THE FIREBOX BE DAMAGED, A SPECIALLY
PREPARED FLEX IS REQUIRED. FOR REPLACEMENT CONTACT THE MANUFACTURER.
THE ON/OFF WALL SWITCH MUST NEVER BE ATTACHED TO A METAL FRAME.
WARNING
Whenever servicing the power flue system, always turn off the electrical power supply and
close the manual gas control valve.
IMPORTANT INFORMATION
In addition to the instructions in this manual all national, state and local regulations must be
adhered to. These include but are not limited to:
• Australian Standards AS3000 - Electrical Installation.
• Australian Standards AS5601 - Gas Installation.
• Local Gas and Electrical Authority Regulations.
• Municipal Building Codes.
The power flue should be serviced every 12 months by an authorised technician. If repairs
are needed an authorised technician must carry them out.
FITTING THE MOTOR
The power flue motor has a 150mm spigot and a twin skin spigot of 150mm & 200mm. The single
spigot fits over the vertical flue and the 150mm/200mm flue attaches to the horizontal spigot.
FLUE SIZE
All flue prior to the motor is 150mm/200mm twin skin and all flue after the motor is
150mm/200mm twin skin. 17

OPTIONAL POWER FLUE (continued)
Installation Instructions (continued)
HORIZONTAL FLUE RUN
The maximum length of horizontal flue run is to be 13.5 metres with a maximum of four (4) bends;
these bends can be 45° or 90°. The horizontal flue run is to have a grade downwards from the
motor to the termination.
VERTICAL FLUE RUN
The minimum vertical flue run is 900mm from the top of the firebox (1500mm from the floor). If a
longer vertical run is required twin skin flue 150mm & 200mm can be added between the muffler
top and the fan. The flue can be cut to the required height.
FLUE CLEARANCES
All flue clearances are as per the requirements listed in the heater specifications.
TERMINATION
The termination to be used for all horizontal installations is to be 150mm cowl that has been
approved as a horizontal cowl.
Installation of Power Flue Kit
POWER FLUE MUFFLER
The power flue muffler has a spigot at each end. The end that attaches to the firebox has a spigot
equivalent to the inner flue spigot diameter of the firebox, the top of the muffler has a 150mm
spigot which the motor fits to, or the 150/200 twin skin flue if required. The flow arrow on the
muffler is to be pointing up.
WIRING (see wiring diagram page 22)
A 3 metre lead is supplied with the power flue, this lead has a different connection on each end,
one end is plugged into the connection on the left hand side of the firebox and the other end is to
be plugged into the fan. The wire coming from the rear of the firebox with the standard 3-pin plug
attached is to be plugged into a power point. A single gang wall switch is also supplied attached
to the 3 metres of lead; this wall switch is to be attached at a location accessible to the client. No
other wiring is required.
SERVICING OF THE POWER FLUE MOTOR
The Real Flame Power Flue motor is designed so as to make servicing the motor a simple task.
The power lead connected to the motor is to be disconnected (unplugged) and the two side clips
are to be undone, the fan motor will then lift out for servicing. The fan Motor box connected to the
flue does not have to be disconnected from the flue.
18

Minimum clearance
250mm
Minimum
height
150mm/200mm
twin skin flue - optional
for additional height
OPTIONAL POWER FLUE (continued)
Ensure there is
adequate ventilation
within this cavity to
prevent motor over-
heating.
Motor Clearance
19

OPTIONAL POWER FLUE (continued)
Motor
Frameout
Fan
Fan Casing
Pressure
Differential Switch
Motor
Motor
Capacitor
4 mf
20
T
IMPORTANT