RealFlame Hot Box Installation instructions

HOT BOX
®
GAS FIREBOX
INSTALLATION & OPERATING MANUAL
The Hot Box Gas Firebox is approved to be installed into a masonary
fireplace and as a zero clearance firebox and is designed to operate on
Natural Gas and Propane (LPG) gases ONLY. Approval Number GMK10100.
Installed primarily as a decorative appliance. Not certified as a Space Heater.
VERSION 19

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 10 years from the date of purchase (Firebox Warranty Period), there is a defect in the firebox of
the Real Flame Gas Burner; or
(b) during the first 12 months from the date of purchase (Parts Warranty Period), there is a defect in the gas valves
or other parts of the Real Flame Gas Burner,
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 Firebox Warranty
Period or the Parts 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; or
(b) it has been installed in an outdoor setting.
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 Firebox Warranty Period or the Parts 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, AS5601-2004 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 AS5601-2004.
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.
VENTILATION REQUIREMENTS
MODEL EFFECTIVE VENTILATION
Hot Box 40,000 sq mm
3
IMPORTANT SAFETY NOTICES
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.
DO NOT MODIFY THIS APPLIANCE.
THIS APPLIANCE IS DESIGNED TO OPERATE WITH LUMINOUS FLAMES. THIS MAY EXHIBIT
SLIGHT CARBON DEPOSITS.
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. It is
recommended that a secondary guard complying with AS-NZS2286 be installed.
THIS IS PRIMARILY A DECORATIVE APPLIANCE AND IS NOT CERTIFIED AS A SPACE HEATER.
SERVICING
It is recommended you service your gas fire every 2 years as a minimum.

CONTENTS
Contents ..................................................................................................................4
Data Plate.................................................................................................................5
Installation Instructions ............................................................................................6
Commissioning Procedure ......................................................................................6
Clearances from combustibles................................................................................7
Installation into an existing fireplace .......................................................................8
Dimensions ..............................................................................................................9
Frameout into room specification sheet 1.............................................................11
Zero Clearance Hot Box ........................................................................................13
Overall Dimensions ................................................................................13
Components...........................................................................................14
Assembly ................................................................................................15
Flue Requirrements ...............................................................................................16
Optional Power Flue ..............................................................................................18
Introduction ............................................................................................18
Installation ..............................................................................................................19
Motor Clearance.....................................................................................21
Frameout ................................................................................................22
Motor exloded view ................................................................................22
Internal Motor .........................................................................................23
External Motor ........................................................................................24
Wiring Diagram.......................................................................................25
Troubleshooting Electronic Ignition and Power Flue System...............................26
Real Flame contact information.............................................................................28
4

NATURAL GAS LPG
DATA PLATE (Affixed to burner)
Injector 2.5 1.3
Mj/Hr 26 23
P. T. P. 0 . 8 2 . 7
5

INSTALLATION INSTRUCTIONS
INSTALLATION INTO AN EXISTING FIREPLACE
The Hot Box system is designed to be installed behind a cast iron insert or fascia.
1. Check that the fireplace and chimney are in working order, sound condition and clean and
free from obstructions. Any cracks or gaps found in the masonary of the fireplace, must be
sealed prior to the installation of the Hot Box.
2. Measure the fireplace opening to ensure that the Hot Box will fit into the opening.
3. If fitting the Hot Box into an existing fireplace, using the existing cast iron insert, you will need
to remove the back from the cast iron insert. This will require the mantelpiece and insert to be
removed from the fireplace prior to installing the Hot Box.
4. Install Hot Box by placing it centrally in the fireplace opening and fit cast iron fascia up to the
Hot Box, ensuring that the fascia is firmly touching against the brickwork of the fireplace and
the Hot Box. Remove fascia and permanently fix the Hot Box to hearth using the location lugs.
5. Before sealing the cast iron fascia to the brickwork have your gas fitter supply a 15mm copper
pipe into the fireplace and Hot Box through the hole provided for connection to the Magiglo
burner.
6. Once the gas supply has been installed into the Hot Box fit and seal the cast iron fascia to the
brick work and install your desired mantel piece to complete your fireplace.
7. Have your gas fitter refer to the Magiglo Series Installation Instructions for connection and set
up of the Magiglo 360 Series Gas Coal Set.
8. A 225mm approved gas cowl is required to be fitted to the top of chimney to stop down draft
and rain entering into chimney.
9. Ventilation of 40,000 sq mm must be provided to outside air for the room that the Hot Box is
installed. Four standard vents is normally enough. Check that they are clear of blockages.
IMPORTANT
After installing gas coal/log set the following commissioning procedure must take place
before leaving premises.
ONLY USE LOGS AND COALS SUPPLIED BY MANUFACTURER.
COMMISSIONING PROCEDURE
Once the fire is installed and operational, the installer must check for spillage. Carry out the lighting
procedure and turn the fire to high. Allow to warm up for 10 minutes and then using a smoke match,
set 25mm down and 25mm inside of the fire opening, run the match across the width of the opening
to check that all of the smoke is drawn away.
Repeat the test with doors and windows to the premises open and closed, and with any extractor
fans in the same room or adjacent rooms running on high. The fire should continue to clear its
combustion products. Also operate any other flued appliances in the same or neighbouring rooms
and ensure they continue to function satisfactorily as multiple flues can work against one another.
If spillage is detected during this procedure it could indicate a faulty flue or lack or ventilation. If the
problem cannot be rectified immediately, disconnect the appliance, and advise the customer not to
use the appliance until the problem has been resolved.
The customer should always be advised of the need for regular servicing and checks to ensure the
continued clearance of combustion waste products.
NOTE: A slight smell may be apparent for first few hours of use. This is due to the heat resistant
paint curing. It is recommended to open windows in room for the first lighting.
6

COMMISSIONING PROCEDURE (continued)
CLEARANCES FROM COMBUSTIBLES
WARNING
Care must be taken to ensure that any return air register exhaust system does not
adversely affect the operation of the appliance or draught of chimney or flue.
“DO NOT place articles on or against this appliance.”
“DO NOT use or store flammable materials near this appliance.”
“DO NOT spray aerosols in the vicinity of this appliance while it is in operation.”
25mm
Cast iron
fascia
DIAGRAM 1. PLAN
425mm
930mm
Floor 0 mm
Sides 25 mm
Back 25 mm
Top 100 mm
Flue Outer 25 mm
Flue can be offset
with two 45° bends,
no more than 20% of
overall height of flue.
NOTE: Install unit
and flue prior to
plastering.
NOTE: Plaster is to
finish flush with the
fascia as shown.
Plaster Fascia
Stud
Firebox
A minimum of 3.6m
flue is required to
protrude 500mm
above roof line.
7
I

INSTALLATION INTO AN EXISTING FIREPLACE
CAST IRON
FASCIA
HOT BOX
GAS INLET
HOLE
MANTEL
PIECE
SEAL FASCIA
TO BRICKWORK
ENSURE THAT EXHAUST PORT
IS NOT RESTRICTED
IN ANY WAY.
EXISTING
CHIMNEY
225mm
GAS
COWL
8For Type 1 installations models with an ODS pilot must be used.

455
260
135
230
570
350
GAS ENTRY
POINT
HEARTH
LOCATION
LUGS
HOT BOX FOR EXISTING FIREPLACE
OVERALL DIMENSIONS
9

DIMENSIONS
AB C
570 455 230
10

D
A
C
B
25mm
90mm x 38mm
ON EDGE
FRAMEOUT INTO ROOM SPECIFICATION SHEET 1
Model A B C D
Hot Box 800 510 425 1800
25mm
FRAMEOUT DIMENSIONS
11
NOTE: Install unit
and flue prior to
plastering.
NOTE: Plaster is to
finish flush with the
fascia as shown.
Plaster Fascia
Stud
FireboxI

CAST IRON
FASCIA
150mm
INNER FLUE
200mm
OUTER FLUE
HOT BOX
GAS INLET
HOLE
MANTEL
PIECE
SPECIFICATION SHEET 1.
FRAMEOUT INTO ROOM SPECIFICATION SHEET 1
12
NOTE: Install unit
and flue prior to
plastering.
NOTE: Plaster is to
finish flush with the
fascia as shown.
Plaster Fascia
Stud
FireboxI

130mm
135mm
305mm
460mm
170mm FLUE INNER 150MM
OUTER 200MM
570mm
GAS ENTRY
POINT
230mm
ZERO CLEARANCE HOT BOX
OVERALL DIMENSIONS
13

INNER CASING
3.6M FLUE KIT
COMPLETE WITH COWL
FLUE COLLAR
OUTER CASING
ZERO CLEARANCE HOT BOX
COMPONENTS
14

ASSEMBLY
ZERO CLEARANCE HOT BOX ASSEMBLY
Using screws provided:
1. Fit inner casing to Hot Box.
2. Fit flue collar to inner casing.
3. Fit outer casing over both flue collar and inner casing.
15

FLUE REQUIREMENTS
Natural Draught
The standard natural draught flue kit consists of 4 x 900mm lengths of twin skin flue (refer to
page 13 for correct sizing) and an AGA approved cowl.
3.6m Flue Kit
complete with cowl
These notes must be read in conjunction with AGA code
601.
Floor 0 mm
Sides 25 mm
Back 25 mm
Top 100 mm
Flue Outer 25 mm
CLEARANCES
A minimum of
3.6m flue is
required to
protrude
500mm above
roof line.
500mm Min.
3.6m Min.
Flue can be
offset with two
45° bends no
more than 20%
of overall height
of flue.
500mm
200mm
2 lengths
above
last bend
Max. 20% of
total flue run
200mm
Min. 3.6m
twin skin
flued
Firebox
16

Power Flue Kit (Optional – refer to pages 18 to 27 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)
FLUE REQUIREMENTS

Electrical
Wiring
between
Fan / Unit / Kit
100mm Gas cowl / Kit
Fan Casing / Kit
Twin Skin Flue 150mm /200mm
Optional for additional height if required
Twin Skin Flue 100mm & 180mm
Baffled Flue / Kit
Powered flue kit comprising:
(Indicated on Diagram as “Kit”)
1 x Fan motor
1 x Control module
1 x Electronic ignition to gas fire
1 x Muffler
1 x Sail switch
1 x All wiring from motor to gas fire
1 x 100mm gas cowl
Twin Skin Flue 150mm/200mm or 200mm/250mm
or 200mm/250mm
17

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
18

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 AS5601-2004 - 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. 19

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 23)
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.
20