RealFlame EXURO IO1000 Installation instructions

EXURO IO1000
INSTALLATION & OPERATING MANUAL
Important: The appliance shall be installed in accordance with;
· Local gas fitting regulations
· Municipal building codes
· AS/NZS 5601.1:2013, Gas installations
· Any other relevant statutory regulations.
· TO BE INSTALLED ONLY BY AN AUTHORIZED PERSON
· THIS APPLIANCE MUST NOT BE INSTALLED OR USED INDOORS
INSTRUCTIONS MUST BE LEFT WITH THE CONSUMER AND THE
CONSUMER TO RETAIN THEM FOR FUTURE REFERENCE.
Approval Number: GMK10105
VERSION 2

2
WARRANTY INFORMATION
The benefits provided to you under the following warranty are in addition to any other rights and remedies available to
you under the law.
1. Warranty
If:
(a) during the first 2 years from the date of purchase (Parts and Labour Warranty Period), there is a defect in the
firebox and all other parts; or
(b) during the first 5 years from the date of purchase (Parts Only Warranty Period), there is a defect in the firebox
only,
due to improper workmanship or material, Real Flame will replace or repair the Real Flame Gas Burner without
charge. Any replacement product is warranted only for the time remaining on the original Parts and Labour
Warranty Period or the Parts Only Warranty Period as relevant.
2. Registration
You must register to receive the benefit of this warranty by completing the warranty registration on our website
(www.realflame.com.au) or completing and mailing the attached registration card within 30 days of purchase of
your Real Flame Gas Burner (or, if the Real Flame Gas Burner is fitted to a new home, within 30 days of the date
of settlement of purchase of such new home).
3. Exclusions
Real Flame is not obliged to replace or repair the Real Flame Gas Burner under clause 1 if:
(a) it has been improperly stored, installed, connected, used, operated or repaired, or damaged, abused, tampered
with, altered (without our written approval), or not maintained in strict accordance with our installation and
operating instructions.
4. Limit of Liability
The warranty provided under this warranty is limited to replacement or repair of the Real Flame Gas Burner only,
at our option. To the extent permitted by law, Real Flame excludes liability for consequential loss or any other loss
or damage caused to property or persons arising from any cause whatsoever, and damage arising from normal
wear and tear.
5. Claiming under the Warranty
In order to claim under this warranty you must, within the Parts and Labour Warranty Period or the Parts Only
Warranty Period (as relevant), contact Real Flame, providing the original proof of purchase and the details below:
Supplier Name___________________________________________________________________________
Date Of Purchase / settlement of property if new home _________________
Model / Serial Number_______________________
This warranty does not cover the cost of claiming under the warranty or transporting the Real Flame Gas Burner to and
from the supplier.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a
replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage.
You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure
does not amount to a major failure.
If you would like to speak to someone about your Real Flame Gas Burner or claiming under this warranty, please
contact the Real Flame Service Warranty Desk on 03 8706 2000.
Real Flame Pty Ltd ACN 006 311 155
Head Office: 1340 Ferntree Gully Road, Scoresby 3179
Telephone: [phone] Facsimile: 03 8706 2001

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, AS/NZS5601.1.2013
installation code for gas burning appliances and any other relevant statutory regulations.
Do not modify this appliance.
In all cases the installation of this appliance shall meet the requirements as set out in
AS/NZS5601.1.2013.
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.
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.
IT IS NOT RECOMMENDED TO OPERATE THE FIRE WITH THE FASCIA PANELS REMOVED.
3
SERVICING
It is recommended you service your gas fire every 2 years as a minimum.

CONTENTS
Contents ..................................................................................................................4
Data Plate.................................................................................................................5
Basic Operation .......................................................................................................6
Removing the Fascia................................................................................................8
Pilot Flame & Burner Positioning.............................................................................9
Maintenance & Cleaning..........................................................................................9
Installation ..............................................................................................................10
Warning...................................................................................................10
Product Description................................................................................11
Dimensions.............................................................................................11
Power Supply..........................................................................................12
Creating the Cavity .................................................................................12
Clearances to Combustibles ..................................................................12
Wall Cladding around fire.......................................................................13
Minimum Install Height...........................................................................13
Types of Installation ................................................................................13
Corner Installations.................................................................................15
Laying Gas Pipe .....................................................................................16
Fixing the Fire into Cavity .......................................................................17
Connecting the Gas Pipe .......................................................................17
Connecting the power supply and power switch...................................18
Testing of the power switch and spark ignition......................................18
Checking Operating Pressure ................................................................19
Assembly of the Glass Feature...............................................................20
Fitting the Fascia ....................................................................................20
Placement of ceramic stones .................................................................21
Optional Weather Cover .........................................................................21
Electrical Schematic...............................................................................................22
Exploded View .......................................................................................................23
Gas Conversion .....................................................................................................24
Real Flame contact information .............................................................................28
4

DATA PLATE (The dataplate for this appliance, containing technical information and specifications can
be found to the right of the control tray, near the base of the fire. To access this, the fascia must first be
removed.
5

BASIC OPERATION
The IO1000 is operated by the switch located on the right hand side outer edge of the fascia. The
basic operations possible are ON/OFF.
Before operating the fire, ensure that the power transformer is plugged into the mains wall socket
and turned on, and the supply is turned on.
Ignition:
To turn the fire on push the ON/OFF rocker switch to the on position. The ignition unit will start
sparking and the pilot and burners will ignite almost immediately.
In the event of no gas, the ignition unit will attempt to try to light up to 3 times before shutting
down.
Turning off the fire:
To turn the fire off, simply flick the ON/OFF rocker switch to the off position. This will shut down the
gas flow to the pilot flame and both burners.
Please ensure the gas supply is also turned off, and as an extra safety please turn off the main
power supply at the house.
CAUTIONS
• Due to its high operating temperature, the appliance should be located out of traffic and
away from furniture and draperies.
• Children and adults should be alerted to the hazards of the high surface temperature, which
could cause burns or clothing ignition.
• Young children should be carefully supervised when they are in the same room as the
appliance.
• Clothing or other flammable materials must not be placed on or near the appliance.
6
ON/OFF
Power
Switch

7
BASIC OPERATION
Propane ULPG Natural Gas
Min. Inlet Pressure 2.5 kPa 2.5 kPa 1.00 kPa
Max Inlet Pressure 5.0 kPa 5.0 kPa 5.00 kPa
Manifold Pressure 2.0 kPa 2.2 kPa 1.00 kPa
Front Burner Jet size Ø1.3 Ø1.25 Ø4.0
Rear Burner Jet size Ø1.3 Ø1.25 Ø4.0
Front Burner Aeration Hole 11mm x 2 off per burner 11mm x 2 off per burner Ø5mm x 2 holes
(NO COLLAR FITTED) (NO COLLAR FITTED) Collar must be fitted -1 off per burner
Rear Burner Aeration Hole 11mm x 2 off per burner 11mm x 2 off per burner Ø5mm x 2 holes
(NO COLLAR FITTED) (NO COLLAR FITTED) Collar must be fitted -1 off per burner
Mj/hour 40 40 49

REMOVING THE FASCIA
8
The IO1000 Stainless Steel fascia is attached to the fire by four ‘hooks’ on the corners of the
fascia. If you need to remove the fascia, lift it upwards and slowly pull it away from the fire in the
same motion.
After the fascia has been unhooked, the short electrical cable attaching the fire to the fascia can
now be unplugged and the fascia can be completely detached.

MAINTENANCE AND CLEANING
9
The unit must be cold before starting any form of maintenance or cleaning.
The glass can be removed and cleaned using standard window cleaner. Be careful not to scratch
the rear of the glass which has a black screen print on it.
To clean the weather cover, warm soapy water should be used.
Cleaning of the burners and ceramic stones can be carried out using a brush and a dry cloth and
should be done at least annually. This will remove carbon or soot build-up. Periodically the pilot
and burners should be checked visually for carbon and soot build-up, a consistent flame and
clean burning.
Fascia:
The Fascia is the visible surround of your Real Flame IO1000 Gas Fireplace and must be treated
carefully to prevent unsightly marks from tarnishing the visual quality of the product. Some
marking over time is inevitable however, so the following directions will assist you in getting the
maximum enjoyment from it.
NEVER EVER RUB THE FASCIA.
The outside of a Real Flame Fascia must only be cleaned with a soft microfibre cloth. If heavier
cleaning is required for the likes of grease or stubborn fingerprint removal we recommend the use
of Steel Kleen brand Ezi Wipes for stainless steel fascias only, and warm soapy water for powder
coated Fascias. These wipes have been tested and produce very satisfying results, when used
correctly. For heavier marks, try the following:
For Stainless Steel Fascias:
• Products such as Steel Kleen ezi wipes applied to the fascia gently in the direction of the
grain have been tested and produce satisfying results when used correctly.
For Powder Coated Fascias:
• Use warm soapy water and a clean soft microfibre cloth to gently clean any marks.
PILOT FLAME AND BURNER POSITIONING

INSTALLATION
10
WARNING
Children and adults should be alerted to the hazards of high surface temperatures, burns and
clothing ignition.
Young Children should be carefully supervised when they are in the area of the appliance.
Clothing or other flammable materials should not be hung from the appliance, or placed on or near
the appliance.
Any guard or other protective device removed for servicing the appliance must be replaced prior to
operating the appliance.
Installation of appliances fitted to fixed gas supply systems and repair of all appliances must be
carried out by a qualified service person.
A qualified service person should inspect and service this product at least annually.
Cleaning may be required in order to keep the control compartment, burners, and circulating air
passageways clean.
The 240/24volt plug pack MUST be installed inside and out of the weather. It MUST be kept dry and
protected from rain and water ingress.
THIS GAS FIRE IS FOR OUTDOOR USE ONLY.

INSTALLATION (continued)
Product Description
11
The Real Flame IO1000 gas fire is designed for outdoor use only. This appliance requires no flue
and must be permanently installed into a cavity. It may be installed into a timber cavity.
The fire is controlled by the user from a switch that is situated on the lower right hand side of the
stainless steel fascia.
The data label which contains all of the technical information such as manufacture date, serial
number, gas type, jet size, etc, can be found in the lower right hand side of the fire, below the
firebox. To access the data plate, the fascia must be removed.
Dimensions

INSTALLATION (continued)
Power Supply
12
This appliance requires a constant external 240V AC 1A power supply to mains electricity.
A plugpack transformer is supplied with the fire.
Creating the Cavity
The dimensioned drawing below shows the size of opening that must be created to install the unit.
AB C
1010 585 330
Where possible, it is recommended that the cavity is made slightly larger than the above
dimensions to give the installer the maximum amount of space to work in.
Minimum clearance distance between a combustible ceiling
and the fascia must be no less than 1400mm.
Warning: Under no circumstances should any object such as
people, pets, furniture, etc. be closer than 1 metre in front of
the IO1000.
Warning: Do not install a TV above this fire under any
circumstances.
Clearances to combustibles

INSTALLATION (continued)
13
Wall cladding around fire
The temperature of the wall directly above the heater does get hot and hence may discolour paint
finishes.
Some dark coloured exhaust stains may also become visible directly above the fire due to
exhaust. In most cases this can be cleaned off with water and a brush.
Minimum install height
The fire has ventilation gaps behind the fascia at the top and bottom. These must not be blocked,
so ensure there is a gap of at least 30mm between the bottom of the fascia and anything below.
Types of Installation
This appliance shall only be used in an above ground open-air situation with natural ventilation,
without stagnant areas, where gas leakage and products of combustion are rapidly dispersed by
wind and natural convection.
Certain materials or items, when placed under or near the appliance, will be subjected to radiant
heat and could become damaged.
The following installation diagrams are Real Flame IO1000 recommendations only and may or
may not comply with your local council standards. Please check with your local council for actual
building standards.
Typically an outdoor space is not enclosed but, any enclosure in which the appliance is used
should comply with one of the following:
1. An enclosure with walls on all sides, but at least one permanent opening at ground level and
no overhead cover.

14
INSTALLATION (continued)
Types of Installation
2. Within a partial enclosure that includes an overhead cover and no more than two walls.
3. Within a partial enclosure that includes an overhead cover and more than two walls, the
following should apply:
• At least 25% of the total wall area is completely open, and
• At least 30% of the remaining wall area is open and unrestricted
Rectangular areas have been used in the above diagrams; the same principles apply to any other
shaped area.
In the case of balconies, at least 20% of the total wall area should be and remain open and
unrestricted.

INSTALLATION (continued)
15
Corner Installations
If a cavity is to be created in a corner, the following drawings give the minimum sized interior wall
dimensions possible.
Note:
Allowances need to be made for cladding the internal of the cavity.
Dimensions of the cavity in this diagram represent the internal size only.
Minimum clearance distance between adjacent wall and fascia needs to be no less than 270mm.

INSTALLATION (continued)
16
Laying Gas Pipe
Gas pipe should be sized as per the requirements of AS5601/AG601-2000. The pipe sizing must
be sufficient to deliver the following volume of gas to the heater with all other gas appliances in
the home running at the same time;
IO1000 Natural Gas = 49 Mj/hr
IO1000 Propane = 40 Mj/hr
IO1000 ULPG = 40 Mj/hr
It is highly recommended to install an easily accessible isolating shut off valve (ball valve) along
the gas line to the IO1000 unit which should be easily accessible to the user.
This fire has been supplied with a ½” pipe connected through a short 45° flare nut inlet connection
to make the gas supply easy and safe. Solid pipe should be run to the inside lower left hand side
of the fire. Insert the supplied rubber plug and cut it as shown below to allow the gas pipe and the
electrical cable to pass through, keeping the plug as air-tight as possible.
Gas Pipe Entry Point
Any flexible pipe should be attached to the copper supply pipe and joint tested to ensure gas
tightness, an isolating valve is recommended for this purpose.
Before each use of the appliance the hose assembly connecting the appliance to the gas supply
must be inspected. If there is evidence of excessive abrasion or wear, or if the hose is damaged,
then the hose assembly must be replaced before the appliance is operated.
The gas hose should be properly located away from pathways or areas where the hose may be
subject to accidental damage.

17
INSTALLATION (continued)
Fixing the fire into the cavity
To fix the fire to the cavity, first drill 4 to 6 (5mm diameter) holes in the outer flange (as shaded
grey in the picture below) in locations which will give you the most support from the cavity
framework behind and evenly spaced around the flange. Using the supplied Stainless Steel
screws, fasten the fire to the cavity through these drilled holes.
Connecting the Gas Pipe
When the fire unit has been pushed into position and secured the flexible hose can be con-nected
to the inlet side of the appliance regulator at the front centre of the fire. The hose and pipe
assembly should have been tested prior to this.
No matter which connection the installer chooses, the regulator that is supplied in the fire MUST
NOT BE REMOVED. Removal of the regulator, or replacing it with one not intended for use with a
IO1000, will void the limited appliance warranty.
The IO1000 must be disconnected from the gas supply piping system during any pressure testing
of that system at test pressures in excess of ½ psi (3.5 kPa).
Ensure that the fire is securely located and free from movement.
Suggested location for screws of mounting:

18
INSTALLATION (continued)
Connecting the power supply and power switch
The power supply socket is located below the firebox. Push the 2 pin plug/socket together with
the supply from the transformer until they ‘click’.
The ON/OFF power switch socket plugs into the 3 pin plug lead situated at the front RH side of
the fire. Push them together until they ‘click’.
Testing of the power switch and spark ignition
IMPORTANT: Before the operating pressure can be checked and the fascia
fitted, the power switch and spark ignition must be tested.
This can be done with the gas supply either turned on or off. With the power supply and power
switch connected, place the fascia beside the fire and run through the steps for igniting the pilot
(refer to page 6 for instructions).

19
INSTALLATION (continued)
Checking Operating Pressure
NOTE: Check ensure that the correct jets, for the gas being used, are installed
– see page 25.
This check is done at the regulator located at the lower front of the appliance.
This must be done before fascia has been fitted.
Pressure test point available for operating pressure (as shown below).
The operating pressure has been factory set. Please check that the operating pressure is exactly
as listed below and if not, adjust the regulator until the pressure is correct. If unable to achieve
this, reassess the inlet gas pressure / pipes.
Replace operating test point screw and leak-test the test point.
Test for overall soundness using an appropriate method.
A = Inlet gas connection
B = Pressure adjustment screw
C = Operating pressure test point
Propane Natural Gas ULPG
Minimum Inlet pressure 2.5 kPa 1.0 kPa 2.5 kPa
Maximum Inlet pressure 5.0 kPa 5.0 kPa 5.0 kPa
Operating Pressure 2.0 kPa 1.0 kPa 2.2 kPa
ABC
Pressure Table

20
INSTALLATION (continued)
Assembly of the Glass Feature
The glass has been packaged seperately to protect it during transit, and can be found inside the
firebox. Carefully insert the glass into the cartridge as shown, between the two metal flanges and
push it all the way to the bottom. Handle the glass with care and avoid scratching it.
Fitting the Fascia
Before fitting the fascia, four hooks must be bent out from the fascia so that they will engage with
the cutouts in the fire. Use your fingers to fold one hook out from each corner so that it sits at 90
degrees to the rear of the fascia. Attach the switch cable from the rear of the fascia to the cable in
the fire and then carefully hang the fascia.
Line up the hooks with the receptacles on the IO1000, and gently push the fascia into position.
The switch should be on the right hand side of the fire. The angle of the hooks can be adjusted if
necessary to ensure a good fit.