RealFlame PYROTECH DELUXE Installation instructions

PYROTECH DELUXE®
INSTALLATION & OPERATING MANUAL
The Pyrotech Deluxe is approved to be installed into a masonry fireplace, as
a zero clearance firebox enclosed by a timber frame and plastered, or as a
free standing unit. The Pyrotech is approved to operate on Natural Gas and
Propane (LPG) gases only. Approval Number GSCS20113.
VERSION 32

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

3
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.
WARNING
The Pyrotech Deluxe has a primary safety glass fitted in front of the glass door. This safety glass is fitted to
this appliance to reduce the risk of injury from burns and at no time should this glass be permanently
removed.
For protection of young children or the infirm, a secondary guard is required.
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.
DO NOT OPERATE WITH GLASS PANEL REMOVED FROM THIS APPLIANCE.
DO NOT MODIFY THIS APPLIANCE.
VENTILATION REQUIREMENTS
ADDITIONAL VENTILATION IS REQUIRED ONLY IF THE UNIT IS INSTALLED IN A ROOM OF LESS
THAN 10 CUBIC METRES IN SIZE - REFER AS5601 CLAUSE 5,4,3,1.
SERVICING
It is recommended you service your gas fire every 2 years as a minimum.

CONTENTS
Contents...................................................................................................................4
Data Plate.................................................................................................................5
Inbuilt Model Dimensions/Installation Procedure ...................................................6
Zero Clearance Model Timber Frame Installation Procedure.................................9
Zero Clearance Model ..........................................................................................10
Zero Clearance Model Assembly ..........................................................................11
Zero Clearance Model Dimensions/Installation Procedure ..................................12
Freestanding Model Dimensions/Installation Procedure......................................13
Flue Requirements.................................................................................................15
Dimensional Drawings...........................................................................................16
Tests to be carried out by installer ........................................................................17
Servicing and Maintenance
Removal of burners ............................................................................................18
Removal of fan....................................................................................................21
Removal of control module ................................................................................21
Removal of control valve ....................................................................................22
Removal of Millennium control module .............................................................22
Parts List.................................................................................................................23
Gas Control Assembly...........................................................................................24
Flue Termination Regulations ................................................................................25
Remote Control Operating Guide .........................................................................26
Optional Marble Surround Installation Procedure ................................................29
Optional Mantelpiece Installation Procedure/Dimensions....................................30
Electrical Diagram..................................................................................................31
Real Flame Contact Information............................................................................32
4

MODEL: PYROTECH DELUXE WEIGHT: 61 kg
INJ/SIZE MJ/H P.T.P.TYPE
2 x 1.65mm 27 1.00kPa HIGH
2 x 1.65mm 16 0.39kPa LOW
2 x 1.0mm 28 2.50kPa HIGH
2 x 1.0mm 18 0.95kPa LOW
NG PRIMARY
APPROVAL NUMBER SERIAL NUMBER DATE OF MANUFACTURE
NG SECONDARY
LPG PRIMARY
LPG SECONDARY
DATA PLATE
TBA
5

PYROTECH INBUILT MODEL
• Unit installed into an existing “working” fireplace requires an AGA approved 150mm gas cowl.
If the chimney does not draw properly, a 900mm length of flexi flue (supplied with unit) should
be fixed to the flue spigot on top of the heater. The flexi flue should be fixed in the vertical
position in a manner that does not allow the flue to fall or come away from the spigot.
• If the fireplace is not a working fireplace, then an approved 100mm flue system with 100mm
AGA approved gas cowl should be used. (Optional extra)
• If the flue is exposed or enclosed with combustible materials, an approved 100/150mm twin
skin flue is required. (Optional extra)
Pyrotech Inbuilt Installation Procedure
Check chimney for correct venting of fumes
Position unit centrally.
Connect to gas supply using 15mm copper union.
Connect to power supply.
Remove glass and assemble log or pebble set as shown (Figures 1 - 12).
TICK BOXES
Figure (1) Remove decorative fasteners from
four corners of shield glass panel.
Figure (2) Remove shield glass panel.
572mm
Gas Pipe
(Alternatives)
Electrical Cord
360mm
865mm
635mm
280mm
600mm
170mm
45mm
30mm
40mm
45mm
240mm
Trim
680mm
370mm
6

Pyrotech Inbuilt Installation Procedure (continued)
Figure (3) Remove nylon grommets and put
aside carefully.
Figure (4) Remove three spacer bolts, and
loosen bolt in bottom right corner.
Figure (5) Support front glass as shown, and
remove fourth spacer bolt. Remove
front glass.
Figure (6) Remove box containing logset, and
unpack. Place the large log at the
rear of the burner just in front of the 2
square tabs on the log support panel.
Re-installation of glass panels is reverse of
above. N.B: ensure that the roped edge of
the glass is fitted to the top.
Figure (7) Place the 14 large coals and 8 small
coals on top of the white ceramic blanket.
Ensure front row of coals are placed
10 - 12mm away from the front grille.
Figure (9) Place the 2 straight logs as shown
Figure (8) Place the 2 ‘Y’ shaped logs as
shown, the larger on the left.
Position the ‘Y’ end of the logs
towards the front of the heater.
PYROTECH INBUILT MODEL
NOTE: Keep coals or pebbles clear
of burner rail.
7

The Pyrotech Space Heater (Natural Gas Only) is approved for use with Pebbles.
To install the Pebbles follow the installation instructions as per Figures 1 to 5 above, and then
proceed as follows (Figures 10 to 12).
Note: If a coals only configuration is being used, use the same set up as pebbles.
Pyrotech Inbuilt Installation Procedure (continued)
Figure (10) Install the metal angle at the rear of
the fireplace and place one row of
pebbles behind the burner rail.
Figure (11) Place pebbles between the first row
and the angled tray.
Figure (12) Place remaining pebbles up the
angle of the rear tray so as the tray
is hidden.
Replace the glass front to its original position.
Fit the trim to the front of the heater.
Light the unit following the procedure on page 22-24.
Install the 150mm AGA approved gas cowl where using the chimney to vent the fumes.
Test the unit for safe operation and show customer correct operating procedures.
Test for spillage.
Perform pressure test.
TICK BOXES
PYROTECH INBUILT MODEL
Note: Keep pebbles clear of burner rail.
8

Pyrotech Zero Clearance Timber Frame Installation
Floor 0 mm
Sides 50 mm
Top 100 mm
Flue Outer 50 mm
CLEARANCES FROM
COMBUSTIBLES
NOTE: Note: If fire is to be installed off the floor with 4
sided trim, use same A, B, C and D dimensions as shown
with frame work included below fire to required height.
Plasterboard to run beyond stud as shown,
and to go behind fixing flange on unit.
Min 50mm
clearance
NOTE
PYROTECH ZERO CLEARANCE MODEL
IMPORTANT
Install unit and
fluing before
plasterboard.
A
A
B
B
CC
D
(Recommended only)
From hearth
Approx 20mm for
hearth if required.
D
(Recommended only)
HEATER
TRIM
Plaster to run
beyond stud
and behind trim
9

PYROTECH ZERO CLEARANCE MODEL
1. Position the Pyrotech firebox in the selected installation position in the room.
2. You will require the Zero Clearance Kit to suit, which is to be fitted to the main fire box as
shown on page 11.
No. Description Qty
1 Panel – Side Strip 2
2 Panel – Top Strip 1
3 Panel – Base 1
4 Panel – Side L/H 1
5 Panel – Side R/H 1
6 Panel – Rear (with cord protector around large hole) 1
7Panel–Top 1
8 Plastic Bag (Containing screws 35 off) 1
9 Cord Protector in place (154mm long) 1
10 100mm Stand Off 4
11. 50mm Stand Off (2 x RH + 2 x LH) 4
12. 25mm Stand Off 4
12. Plastic Bag Self Tapping Screws 1
ZERO CLEARANCE KIT COMPONENTS
FLUE KIT
10

1. Secure side strips (Item 1) to side brackets on
fire box using screws (2 off per side strip).
Remove 2 top screws in fire box and place top
strip (Item 2) into position and secure using 2
screws.
Place base panel (Item 3) under fire box.
2. Place LH side panel (Item 4) in behind lip of
base panel. Secure side panel to side strip and
base panel in 6 places.
Repeat for RH side panel (Item 5). Place rear
panel (Item 6) in behind folds on side panels and
base panel. Secure rear panel using screws
9 off.
3. Place top panel (Item 7) onto assembly. Ensure
all other panels sit behind folds on top panel.
Secure top panel 9 places around edge and 1
screw on the top in the centre passing through
hole in top strip as shown.
PYROTECH ZERO CLEARANCE MODEL
Fit Zero Clearance Kit to unit as shown below:
ITEM 2 ITEM 5
ITEM 6
ITEM 4
ITEM 1
ITEM 3
ITEM 7
11

Pyrotech Zero Clearance Installation Procedure
Connect to gas supply.
Connect to power supply
Install flue to 500mm minimum above roof line. (Min total flue run 3.6 m)
Plaster to unit with trim removed.
Install trim.
Assemble unit as per page 11.
Test the unit for safe operation and show customer correct operating procedures.
TICK BOXES
PYROTECH ZERO CLEARANCE MODEL
610mm
400mm
280mm
865mm
635mm
675mm
Trim
Gas Inlet
Power Inlet
12

PYROTECH FREESTANDING MODEL
840mm
50mm
50mm
40mm
40mm
460mm
780mm
Ceiling Ring
Ceiling Ring
4 x 900m
Flue Lengths
Cowl
740mm 460mm
30mm
STANDARD FLUE KIT
Gas
Power
13

Pyrotech Freestanding Installation Procedure
Position unit maintaining correct clearances from combustibles.
Connect to adequate gas supply.
Connect to adequate power supply.
Install flue kit maintaining minimum 25mm clearances from outer flue to combustibles.
Assemble as per pages 5 - 7.
Ensure clearances noted below are maintained.
A
B
B
B
C
C
TICK BOXES
PYROTECH FREESTANDING MODEL
Min 3.6 m
Min
2 x 900 mm
A50 mm
B50 mm
C500 mm
MINIMUM CLEARANCES
FROM COMBUSTIBLES
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

I
AB CDEF G
570 592 360 700 54 275 35
AB CDEF GHI
610 700 464 675 125 402 95 45 25
DIMENSIONS
Pyrotech Inbuilt
Pyrotech ZC
B
A
FRONT - 4 SIDED FRONT - 3 SIDED
C
AB C
865 730 635
Trim
16

TESTS TO BE CARRIED OUT BY INSTALLER
• Check unit for gas leaks.
• Ensure that both high and low pressures are set as per the appliance data plate.
Refer Page 23 for adjustment and Test pressure points
• Turn the unit on to ensure it operates correctly.
• Instruct the customer on the use of the remote control . Refer to remote control
operating guide.
AB CDEF GH
840 740 460 780 30 420 115 315
DIMENSIONS
Pyrotech Freestanding
17

Figure (1) Remove top louvre panel.The top
panel is held by a screw each side.
Figure (3) Remove front safety glass by firstly
removing four dome nuts.
Figure (5) Remove four door studs used to
secure the door.
Figure (7) Remove door carefully to prevent
damage or breaking of glass.
Figure (2) Remove bottom panel by opening
door and pulling back location pin.
Figure (4) Remove glass from its location, be
sure to avoid breakage or damage to the
glass when removing.
Figure (6)
SERVICING AND MAINTENANCE
To follow when servicing,
removing fan or changing
valve or control modules.
IMPORTANT: POWER MUST BE
ISOLATED PRIOR TO CARRYING
OUT THE SERVICE/MAINTENANCE.
SERVICE/MAINTENANCE ONLY TO
BE CARRIED OUT BY AN
AUTHORISED PERSON.
18

Figure (8) Remove coals/logs or pebbles and
securely store to prevent damage.
Figure (10) Remove front iron from burner.
Figure (12) Remove log positioning panel
screw at rear of firebox.
Figure (14) Undo burner tube nut using
15mm spanner.
Figure (9)
Figure (11) Remove burner holding screws
on each side of burner.
Figure (13) Remove log positioning panel.
Figure (15) Remove the two pilot screws to
disconnect pilot.
19

Figure (16) Remove burner from firebox
Figure (18) ...and the sides of the base.
Figure (20) Undo the flexi tube from the bulk
head.
Figure (22) ...remove the base plate from the
firebox.
Figure (17) Remove the nine screws securing
the base to the firebox from the back of the
base...
Figure (19) Lift the base plate to expose the
flexi burner tube.
Figure (21) When the flexi tube has been
unscrewed...
Figure (23) Once the base plate has been
removed, all controls are exposed for
servicing.
20