RealFlame Hybrid 850 Installation instructions

HYBRID
DECORATIVE FIREBOX
INSTALLATION & OPERATING MANUAL
Hybrid fire boxes are approved to be installed as a zero clearance
firebox and are designed to operate on Natural Gas and Propane (LPG)
gases ONLY.
Approval Number: GMK10099
Installed primarily as a decorative appliance. Not certified as a Space Heater.
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 15 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 2 years 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, AS/NZS 5601.1-2013 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 AS/NZS 5601.1-2013.
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.
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.
SERVICING
It is recommended you service your gas fire every 2 years as a minimum.
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.
VENTILATION REQUIREMENTS
MODEL SIZE EFFECTIVE VENTILATION
HYBRID 850 32,000mm2
HYBRID 1000 50,000mm2
HYBRID 1500 72,000mm2
HYBRID 1800 72,000mm2
HYBRID 3300 144,000mm2
3
NOT INTENDED AS A FIREPLACE INSERT.

CONTENTS
Contents ..................................................................................................................4
Data Plate.................................................................................................................5
Zero Clearance Modular Installation & Dimensions ................................................6
Dimensions Hybrid 850............................................................................................7
Dimensions Hybrid 1000..........................................................................................8
Dimensions Hybrid 1500..........................................................................................9
Dimensions Hybrid 1800........................................................................................10
Dimensions Hybrid 3300........................................................................................11
Zero Clearance Modular Installation
Timber Frame Installation .......................................................................12
Installation Check List.............................................................................13
Lighting/Testing and Failure Procedure.................................................................14
Flue Requirements (Standard) ..............................................................................15
Flue Requirements (Power Flue Kit) ......................................................................16
Optional Power Flue...............................................................................................17
Introduction.............................................................................................17
Installation...............................................................................................17
Motor Clearance .....................................................................................20
Frameout.................................................................................................21
Motor.......................................................................................................21
Internal Motor..........................................................................................22
External Motor ........................................................................................22
Dimensions.............................................................................................23
Troubleshooting Electronic Ignition and Power Flue System................25
Wiring Diagram.......................................................................................27
Parts ................................................................................................................28
Marble Bases & Fronts...........................................................................................29
Real Flame contact information .............................................................................32
4

DATA PLATE (Affixed to the base of the unit for reference to gas pressure & consumption)
5
Hybrid 850 & Hybrid Signature 850
Fitted with Magiglo 540 or 540EI burner
Gas Injector Size (mm) TPP N.G.C. (Mj/Hr)
Natural Gas 2 x 2.25 0.80 kPa 37
ULPG 2 x 1.10 2.60 kPa 33
Hybrid 1000 & Hybrid Signature 1000
Fitted with Magiglo 750 or 750EI burner
Gas Injector Size (mm) TPP N.G.C. (Mj/Hr)
Natural Gas 3 x 1.85 0.75 kPa 39
ULPG 3 x 0.95 2.55 kPa 34
Hybrid 1500 & Hybrid Signature 1500
Fitted with 1000 or 1000EI burner
Gas Injector Size (mm) TPP N.G.C. (Mj/Hr)
Natural Gas 3 x 2.25 0.75 kPa 49
ULPG 3 x 1.10 2.60 kPa 49
Fitted with 1200 burner
Gas Injector Size (mm) TPP N.G.C. (Mj/Hr)
Natural Gas 4 x 2.20 0.80 kPa 55
ULPG 4 x 0.95 2.55 kPa 48
Hybrid 1800 & Hybrid Signature 1800
Fitted with 1400 or 1400EI burner
Gas Injector Size (mm) TPP N.G.C. (Mj/Hr)
Natural Gas 4 x 2.25 0.85 kPa 60
ULPG 4 x 0.95 2.55 kPa 48

ZERO CLEARANCE MODULAR INSTALLATION
• The Firebox is designed to be installed into a new frame out as shown on page 12.
• The fire can be installed at ground level or raised to what ever height is required providing
the flue length is 3.6 meters or more.
• The firebox can sit directly onto a wooden surface.
• The Firebox requires twin skin flue with an AGA approved cowl (or optional Power Flue –
refer pages 17 to 27)
• The control valve on the Firebox is an electronic ignition system and as such, electrical
work is required.
Overall Dimensions (in mm)
MODEL Size Inner Outer
HYBRID 850 200 250
HYBRID 1000 250 300
HYBRID 1500 300 350
HYBRID 1800 300 350
HYBRID 3300 300 x2 350 x2
POWER FLUE (optional) BEFORE MOTOR 150 200
AFTER MOTOR 150 200
Flue Sizes (in mm)
Right Hand Hybrid shown
MODEL A B C D E
850 920 950 450 570 155
1000 920 1100 450 570 155
1500 1000 1600 450 500 190
1800 1140 1900 450 500 190
3300 1135 3400 450 500 190
D
B
E
A
C
12mm Gas Line
Inlet Point
Connection to Power Flue
or electronic ignition
(Optional)
125c
90c Power Lead
(Optional)
REAR OF FIREBOX
130c
100c
70c
90c
6

J
J
DIMENSIONS
Hybrid 850 - Left Hand Model
Hybrid 850 - Right Hand Model
AB CDEF GH
920 950 450 570 165 335 230 150
IJKLMNO
400 120 50 10 50 520 350
7

DIMENSIONS
Hybrid 1000 - Left Hand Model
Hybrid 1000 - Right Hand Model
AB CDEF GH
920 1100 450 570 165 335 230 150
IJKLMNO
400 120 50 10 50 520 350
8

F
C
A
D
J
I
N
G
K
L
B
M
E
O
H
12 5
87
130
10 0
70
F
C
A
D
J
I
N
G
K
B
M
E
O
H
DIMENSIONS
Hybrid 1500 - Left Hand Model
Hybrid 1500 - Right Hand Model
AB CDEF GH
1000 1600 450 500 190 370 215 300
IJKLMNO
330 120 50 10 50 450 500
9

F
C
A
D
J
I
N
G
K
L
B
M
E
O
H
87
12 5
87
130
10 0
70
F
C
A
D
J
I
N
G
K
B
M
E
O
H
DIMENSIONS
Hybrid 1800 - Left Hand Model
Hybrid 1800 - Right Hand Model
AB CDEF GH
1135 1900 450 500 190 370 215 435
IJKLMNO
330 120 50 10 50 450 635
10

DIMENSIONS
Hybrid 3300 - Left Hand Model
Hybrid 3300 - Right Hand Model
AB CDEF GH
1135 3400 450 500 190 370 215 435
IJKLMNO
330 120 50 10 50 450 635
11

Timber Frame Installation
ZERO CLEARANCE HYBRID INSTALLATION
IMPORTANT
Install unit and
fluing before
plasterboard.
C
D
(Recommended only)
Floor 0 mm
Sides 25 mm
Top 100 mm
Flue Outer 25 mm
CLEARANCES FROM
COMBUSTIBLES
NOTE: All Hybrid fires and flue kits are
to be installed PRIOR to plasterboard.
Plasterboard is to be run past stud frame
and up to fire opening terminating in
square edge.
MODEL A B C D
HYBRID 850 1020 1000 475 2100
HYBRID 1000 1020 1150 475 2100
HYBRID 1500 1100 1650 475 2100
HYBRID 1800 1235 1950 475 3000
HYBRID 3300 1235 3450 475 3600
Frameout Dimensions (in mm)
12
A
Plaster to run
beyond stud and
finish to edge of
opening
Do not block air
intakes
HEATER
B
Right Hand Hybrid shown

Installation Procedure
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. If the
flue needs to be off set with 45 deg bends, the offset length can be no more than 20% of the total
flue run. It is recommended that after the last bend at least two full lengths of flue are added in the
vertical.
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 back of the firebox. A
500mm tail is required into the firebox to allow for connection to the burner.
Position the unit ensuring the wiring loom and gas pipe are accessible.
Connect the twin skin flue (or Optional Power Flue if supplied).
Install an AGA approved gas cowl ensuring the termination meets all relevant code requirements.
Connect the gas line to the burner connection using the 15mm flared copper union (supplied).
Connect the wiring terminals to the ignition pack as shown below.
Note: Do not locate the switch further than 6 meters from the firebox.
Place the burner surround or optional front or marble base 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.
TICK BOXES
ZERO CLEARANCE HYBRID INSTALLATION
DO NOT BLOCK
INTAKES ON INSTALL
DO NOT BLOCK
INTAKES ON INSTALL
13

FOR YOUR SAFETY READ BEFORE LIGHTING
Before igniting the fire, check for gas leaks.
Use only the ignition components supplied.
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.
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information before proceeding.
2. Turn on the remote wall switch.
• If the fire will not stay lit after several tries turn the switch to “OFF” and call your service
technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Turn off the remote wall switch.
LIGHTING MAIN BURNER
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.
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. Ensure that the wiring terminals are not loose.
2. Test that the inlet and working pressures are both correct.
If when the wall switch is turned to the “ON” position and the fire fails to ignite, check the
following:
14

FLUE REQUIREMENTS
Natural Draught
The standard natural draught flue kit consists of 4 x 900mm lengths of twin skin flue (refer to
page 6 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
15

Power Flue Kit (Optional – refer to pages 17 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
16

INTRODUCTION - THE POWER FLUE SYSTEM
INSTALLATION INSTRUCTIONS
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.
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. Refer page 19.
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. The device should ALWAYS be in the vertical position. Refer to the
pressure differential switch on page 11.
‘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.
17

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
1a. Below eaves, balconies and other projections for a 1500 & 1800 model .................300mm
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 AS/NZS5601.1-2013 - 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 is fitted with two sets of spigots. The set on the base of the Power Flue box
sit on top of the vertical flue and the set mounted on the side plate connect to the horizontal flue.
The 1800 and 3300 units have a power flue motor with a 200mm spigot and a twin spigot of
200mm and 250mm.
18

INSTALLATION INSTRUCTIONS (continued)
INSTALLATION OF POWER FLUE KIT
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 (see page 8)
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. For 1800 and 3300 units
200mm/250mm flue is required.
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 either a small flush cowl or if
used as a service access panel, a large flush cowl is required. For vertical termination a vertical
approved cowl must be used. An external motor can be used as an option on horizontal and
vertical terminations.
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. If a 1800 or 3300 unit is used the flue is 200mm/250mm.
WIRING (see wiring diagram pages 17 & 18)
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 screws 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.
FLUE SIZE
The flue size for each model is different. Please refer to the table below.
19
B
A
MODELS A mm B mm
Double Vision, Hot Box and all Heatseekers 150 200
Pure Vision, Simplicity, Elegance, Signature,
Hybrid 850, 1000 & 1500 Sizes 150 200
Pure Vision, Simplicity, Elegance, Signature,
Hybrid 1800 & 3300 Sizes 200 250
NOTE: Ensure all power flue inner and outer flue lengths are sealed at joins.

POWER FLUE MOTOR CLEARANCE
Minimum clearance
250mm
Minimum
height
150mm/200mm
twin skin flue - optional
for additional height
Ensure there is
adequate ventilation
within this cavity to
prevent motor over-
heating.
Baffle Height 980mm
and diameter 350mm
or 200mm/250mm
20