Royal Cozyfires Royal Belmont G20 User guide

0102 095 50721
LFE MKII
ROYAL BELMONT
USERS (Pages 2-3)/ INSTALLATION (Pages4-8)
AND SERVICING INSTRUCTIONS
THIS CAT I2H APPLIANCE IS FOR USE
ON NATURAL GAS G20 AT A SUPPLY
PRESSURE OF 20 mbar IN GB and IE
HAND THESE INSTRUCTIONS TO THE USER

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This Royal Cozy Fires Inset Live Fuel Effect gas fire has been developed to give a realistic coal burning appearance
with the instant control and convenience of gas. The fire has been constructed to enable it to be installed into most
applications where the warmth and comfort of an open fire with high radiant and convection heat is required. The
coal bed uses ceramic simulated ‘coals’ and is to give a realistic appearance and to allow secondary air to be
entrained into the bed to ensure clean combustion. An aerated twin ported steel burner is used, running parallel across
the front of the fire combined with a single gas control with a variable high / low setting. This is fitted with a Flame
Supervision Device (FSD) to ensure that should the pilot flame be extinguished for any reason, (including turning off
the appliance), the gas supply to the burner is cut off until a full lighting sequence is repeated. A separate Piezo
igniter is used to ignite an oxy-pilot sensor (ODS), this will cause the appliance to ‘shut off’ in the event of the flame
extinguishing and also in the event of continued spillage occurring under hazardous or blocked flue conditions. The
fire bed consists of ceramic fibre components and coals, all are removable for cleaning purposes when required. It is
important when relaying the coal bed and coals to follow the instructions correctly.
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This appliance has been designed and manufactured to the requirements of the British Standards Institution BS 5258
Part 16 1990 and is for use on Natural Gas Only.
All gas appliances must be installed by a competent person in accordance with the current Gas Safety (Installation
and Use) Regulations 1994 (as amended) or the rules in force and in accordance with the manufacturers instructions,
failure to do so could lead to prosecution.
The chimney or flue (unless new) must be swept before installation. It is recommended that the appliance is serviced
annually by a competent person and the flue checked for satisfactory clearance of products and that there is no
excessive build up of soot. The curing effect of heating the coals will cause an initial odour which, although not
harmful, may require additional ventilation until the odour has disappeared.
The appliance has a naked flame, a fireguard conforming to BS 6539 or BS 6778 should be used for the protection of
the very young, elderly and infirm. Combustible materials should not be put on or left in the hearth nor should the
coal bed be used to burn rubbish or other materials.
Care must be taken on the selection of wall coverings within close proximity of the fire as some vinyl and embossed
materials may be become discoloured by convection heat. Soft furnishings must be kept clear from the radiant heat of
the fire and from impinging the hearth area. The hearth must not be covered by any combustible materials such as
carpets etc.
This product uses fuel effect pieces, gaskets and insulation material containing Refractory Ceramic Fibre (RCF),
which are man-made vitreous silicate fibres. Excessive exposure to these materials may cause temporary irritation
to eyes, skin and respiratory tract, consequently, it makes sense to take care when handling these articles to ensure
that the release of dust is kept to a minimum.
This fire will run for 5.4 hours on one therm of gas with the gas control on the high setting.
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1. Remove the fret by lifting upwards (controls cover).
2. Press and turn the gas control until the indicator mark is opposite to IGN keeping the control fully depressed.
Press and release the ignition button. Check that the pilot flame has lit at all ports. Keep the gas control
depressed for a further 20 seconds. Release the gas control and check the pilot remains alight.
3. Depress the gas control slightly and turn fully anti-clockwise until the indicator is opposite the small flame
symbol. The burner will now ignite from the pilot assembly and run at the low rate.
Page 2

4. Depress the gas control slightly and turn clockwise until the indicator mark is opposite to the large flame
symbol. The burner will now run at its maximum rate.
5. To turn the appliance ‘off’, return the control to the ‘off’position.
6. If for any reason the fire cuts out, return the control knob to the ‘off’position and wait 3 minutes before re-
lighting.
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Allow the appliance to cool sufficiently before removing all of the coals and firebed components for cleaning
purposes. Once all the ceramics are removed from the firebed check that no debris is located in the burner slots
(both front and rear). If any debris is present it may easily be removed by using a small piece of thin cardboard to
ease out any foreign matter. Be sure to remove the cardboard after use. Should any soot accumulation become
excessive, the fuel effect pieces should be removed from the fire for cleaning. Cleaning should be carried out in a
well-ventilated area or in the open air, by gently brushing with the pieces held away from your face so that you
avoid inhaling the dust. We do not recommend the use of a normal domestic vacuum cleaner, which may blow
dust back into the air. Any sooty deposit on the thermocouple probe can be cleaned off using a non-fluffy cloth.
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1. Locate the fibre back/side cheeks in position.
2. Place the coal support shelf on the stainless steel channel, (the machined groove on the underside of the shelf is
located on the rear flange of the channel), two additional location dowels are fitted to prevent the shelf being
incorrectly placed.
3. Place the two shaped burner inserts in channel between the two burner flame ports, (check that a minimum gap of
approx. 6mm is maintained between the rear of the burner insert and the front edge of the coal support shelf).
4. Position the front simulated coal on the shelf provided above the control facia panel.
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Position 3 large coals, 2 triangular and 4 large coals on edge (straddle the gaps of the coal support shelf and run
the strata front to rear) as the first layer (fig. 21). Place 4 medium as a second layer sitting on the gaps of the front
coals and resting against the rear coals.(fig 22). Finally place the remaining 5 small coals as shown in fig 23. Small
adjustments to the coal layout may be made to give the best visual appearance however, additional coals must
not be used. If any fibre component is lost or broken the appliance must not be used until a replacement is
obtained.
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Additional purpose built ventilation is not required for this appliance in GB only, for Ireland (IE) ventilation is
required with a minimal cross sectional area of 100 sq. CMS and should be checked regularly to ensure that it is free
from obstruction.
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Minimum clearance required to any combustible material to the side of the appliance must be 150mm.
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Minimum clearance to the underside of a 150mm deep combustible shelf from the hearth must be 833mm. Add
12.5mm to this clearance for every 25mm increase in depth of shelf.
Page 3

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All gas appliances must be installed by a competent person in accordance with the current Gas Safety (Installation
and Use) Regulations 1994 (as amended) or the rules in force and in accordance with the manufacturers instructions,
failure to do so could lead to prosecution
The following are the relevant Codes of Practice and British Standards.
BS 8303 1986 BS 5440 Pt1 1990 & Pt2 1989The Building Regulations issued by the
BS1251 1987 BS 5871 Pt2 1991 & Pt3 1991Department of the Environment. The
BS 6891 1988 BS 6461 Pt1 1984 Building Standards Scotland)(Consolidation)
BS 715 1989 BS 1289 Pt1 1986 Regulations issued by the Scottish Development
BS 7566 Pts 1-4 1992 Department.
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Overall height of fire = 614 mm
Minimum height of opening required = 550 mm
Maximum height of opening = 590 mm
Minimum width of opening required = 395 mm
Maximum width of opening with spacer = 470 mm
Forward projection from opening = 140 mm
(With controls cover)
Min depth of openings See Figs 1-8
TYPE OF GAS G20 Only Supply Pressure 20 mbar +/- 1mbar (Cold)
GAS INPUTS (Gross) Maximum 5.42 kW (18500 Btu/h)
Minimum 2.34 kW (8000 Btu/h)
Pilot 0.26 kW (890 Btu/h)
Main Injector Type Bray Cat 82/380
Or Stereomatic 046/19/196/68M
Pilot Assembly SIT Oxy/Pilot NG 9022
GAS CONNECTION 8 mm O/D Tube
WEIGHT 22 kg
Note: None of the materials used in the manufacture of this appliance contain asbestos.
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Care should be taken to ensure when the appliance is installed into a Pre-cast flue, the chimney breast is lined to
prevent the plaster etc, cracking through excessive temperatures.
A certain amount of discolouration (blueing) may be seen on the stainless steel combustion chamber, this is normal
due to the temperatures produced in the fire bed.
A hearth must always be provided, a minimum of 340mm and a minimum of 150mm either side of the fire opening
with a minimum thickness of 12mm and a perimeter height of 50mm. This is to deter combustible materials, carpets
etc, being placed on the hearth.
The area under the firebox must have a minimum non-combustible thickness of 25mm.
Page 4

In most installations a back panel will be required, this will also need a minimum fire resistance rating of Class O
(100 C).
Check that the chimney and flue structure are sound and conform to the following flue requirements:
1. A conventional brick or stone chimneys with a minimum effective cross sectional dimension of 225x225 mm. A
lined flue with a minimum diameter of 175 mm having a chair brick and throat forming lintel conforming to BS
1251 or a builders opening measuring 550 mm high x 400/470 mm wide with a sufficient depth for debris
collection. If a chair brick is fitted, a minimum depth requirement for the appliance is shown in Figs 2 & 3, if
insufficient depth is available, the chair brick will have to be removed.
2. A twin walled metal flue box manufactured to BS 715 with a twin walled 125 mm diameter flue and a minimum
effective flue height of 3 metres. See Figs 4 & 5.
3. A pre-cast flue conforming to the requirements of BS 1289 Pt 1 1986 and BS 1289 1975 including properly
constructed pre-cast flues with a cross sectional area of 13000sq mm. See Figs 6 - 8.
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Dampers, register plates or incorrect flue terminals, must not restrict the flues listed above. The flue must only service
a single appliance and not have any branches or traps that may impede the natural draught. Any flue damper plate or
restrictors shall be removed or fixed in the fully opened positions.
The front and base of the fire opening must be flat and square to ensure a good seal with the appliance; this is to
ensure that there is no reduction in draught through the fire, which may cause spillage to occur.
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Convector Box and Front Trim (Goal Post) Burner Unit
Burner Inserts Coal Support Shelf
Fibre Back Set of Coals –7 Large, 4 Medium, 2 Triangular
Front and Fret and 5 Small.
Short length of Bundy 43mm Concealed Supply Pipe
In-line Connector RH Conversion Supply Pipe
Users / Installation and Servicing Instructions Plastic Fixing Plugs 4 off
Wood Screws 4 off Installation Brackets
M4 x 10 Screws
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7in Diameter Flue, Chair brick and Builders opening (Class 1). See Figs 2 & 3.
5in Diameter Flue and Metal Flue Box (Class 2). See Figs 4 & 5.
Pre-cast Flues. See Figs 6 –8.
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IMPORTANT: Restrictor plates must be removed. See Fig 15.
When the metal flue box is to be built-in as a false chimney-breast using timber stud work with a plasterboard facing,
the metal flue box should be enveloped with insulation material such as Rockwool or similar to prevent a build-up of
heat within the structure. Either an air gap of 75mm should be maintained between any combustible materials and
any part of the metal flue box or a minimum of 25mm of insulation material between the metal flue box and the
combustible material. It is important that both the back panel and the appliance are sealed to the metal flue box to
prevent any leakage of flue products or reduction in the flue draught. See Figs 4 & 5.
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IMPORTANT: Restrictor Plates must be removed. See Fig 15.
See Figs 6 –8.
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Check that the chimney conforms to the required specifications as previously stated. Examine the condition and
carry out any remedial work as necessary, if the flue has been used for solid fuel it should be swept and a smoke test
carried out to check that satisfactory smoke clearance has been established. If all the smoke is not drawn into the flue,
pre-heat the flue with a blowtorch or similar and re-check. If there is any uncertainty examine for the cause and if
necessary seek expert advice.
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BEFORE COMMENCING WORK, TURN OFF ANY APPLIANCES THAT ARE FED BY THE METER
AND ISOLATE THE GAS SUPPLY BY TURNING OFF AT THE METER
The gas connection to this appliance is made with 8mm o/d rigid or semi rigid tube to a pressure test elbow situated
on the L/H side of the burner as shown below. It is advisable to provide a means of isolating the gas supply to the
appliance for servicing with either a restrictor elbow or isolation cock such as shown below. Provision is made in the
rear L Hand corner of the outer casing to allow a gas supply to be fed to the burner assembly. A blanking plate and
gasket is supplied with cutouts and slots that will enable a seal to be made around the supply pipe. If a restrictor
elbow is to be used, it will be necessary to cut and form the bundy pipe supplied. Any pipe used under the burner
must be in rigid tube such as Bundy, 3 pieces of Bundy are included in the fitting kit to assist the installer. (a) A short
piece for use with a restrictor elbow. (b) A formed section for connection to an isolation cock, and (c) a formed
section for R Hand supply using the inline connector supplied. The inlet pipe support bracket can be removed if
necessary to gain greater access, by unscrewing the Control mounting lock nut and lifting over the spindle, as shown
in Fig 9.
Where a concealed gas supply is used, the installer is reminded of the requirements of BS 6891 1988 dealing with
enclosed pipes. The Standard requires that when a gas pipe is fed through a wall, the pipe should be enclosed in a
tight sleeve to protect against failure caused by movement and shall be constructed to prevent passage of gas either
between the pipe and sleeve or sleeve and wall.
Permanent sealant e.g. fire cement etc. should not be used as these would prevent removal of the firebox if so
required.
Page 6

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The lower front panel assembly is removed by lifting upwards and pulling forwards. Remove the canopy to gain
access to the Bezel or (Goal post trim) securing screws. The canopy is held in position by dimpled spring clips on
both the side flanges, remove by exerting an even pull forward. See Fig 11.
Remove the outer bezel/Goal post trim by unscrewing the four M4 taptite screws on the inner flanges and the four No
8 self tapping screws in the corners.
It will be necessary to dismantle the burner from the convector box before installing the box in the opening, to
remove the burner, unscrew the two screws securing the fibre back/ side cheek assembly in position and remove,
remove the coal support shelf and burner inserts. Unscrew the two screws at the base of the aperture in the fascia
panel and withdraw the burner.
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With the gas supply pipe laid to the required position and the surround fitted and sealed to the chimney correctly –
this is to prevent any seepage of the flue products and to prevent any ingress of air into the flue from anywhere other
than the flue outlet of the fire. The method to be used to secure the appliance in position is either screwed directly
onto the front face of the back panel through the mounting brackets or fixed to the internal side walls of the builders
opening using the four fixing brackets provided. These can be rotated to accommodate most openings, as shown in
Fig 14: plastic plugs and wood screws are supplied for these brackets.
It is very important when fitting the trim, that when it is secured in position, that the rear of the trim has an effective
seal with the back panel or fixing wall. ( A seal is fitted to the trim during manufacture).
Continue the supply and replace the burner ensuring that the rear legs locate in the two up-formed tags in the base
plate and complete the gas connection to the burner. Replace the canopy.
NOTE: Before offering the convector box into the opening, the hearth should be protected from damage or scratches
that may occur during installation.
The complete installation should be tested for Gas soundness.
IT IS VERY IMPORTANT THAT THE RESTRICTOR PLATES ARE REMOVED AND THE SCREWS
REPLACED WHEN THE APPLIANCE IS INSTALLED INTO EITHER A PRE-CAST OR A 5in (125mm)
DIAMETER FLUE.
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1. Locate the fibre back/side cheek assembly in position.
2. Place the coal support shelf on the stainless steel channel, the machined groove on the underside of the shelf is
located on the rear flange of the channel.
3. Place the two shaped burner inserts in channel between the two burner flame ports, (check that a minimum gap of
approx. 6mm is maintained between the rear of the burner insert and the front edge of the coal support shelf).
4. Position the front simulated coal on the shelf provided above the control facia panel. See fig 20.
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Position 3 large coals, 2 triangular and 4 large coals on edge (straddle the gaps of the coal support shelf and run
the strata front to rear) as the first layer (fig. 21). Place 4 medium as a second layer sitting on the gaps of the front
coals and resting against the rear coals.(fig 22). Finally place the remaining 5 small coals as shown in fig 23. Small
adjustments to the coal layout may be made to give the best visual appearance however, additional coals must
not be used. If any fibre component is lost or broken the appliance must not be used until a replacement is
obtained.
Page 7

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Turn on the Gas supply at the meter and to the appliance at the isolating cock. Purge the air to the appliance. Rotate
the control knob to the ignition position, depress the control and push the piezo to ignite the pilot. Check that the
electrode is sparking between the tip of the thermocouple and continue until a pilot ignition is established. Depress
the control knob slightly and rotate anti-clockwise until the index symbol is aligned with the small flame symbol on
the indicator label, release and rotate the control knob to the high position (large flame symbol). Check that the flame
picture is satisfactory prior to carrying out the spillage test.
To check the gas pressure at the appliance, allow the coals and the coal bed to cool and turn off the gas supply at the
isolating cock. Remove the hexagon headed screw and connect a manometer to the pressure test point, turn on the gas
and ignite the fire, allow to heat up and check that the gas pressure is 20 +/- 1 mbar - any appreciable drop may
indicate losses through the pipework. The pressure test point may also be used to check for leakage of the joints to the
appliance. Allow the coal bed to cool before replacing the screw.
Turn the gas control to the OFF position, wait for 90 seconds, fully depress the gas control, turn to the ignition
position and release the control. Attempt to light the pilot with an already prepared match or taper. If the pilot lights
the FSD is faulty.
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Light the appliance and set to the maximum setting, locate the front and fret in position and leave to warm up for
approx. 5 minutes. Check for satisfactory clearance of combustion products by inserting a lighted smoke match on a
vertical plane 30mm down, 10mm inside the rear edge of the inner canopy and 70mm from the left hand side of the
opening. All the smoke must be drawn into the flue. If spillage occurs, allow a further 10 minutes. Should spillage
still occur, examine the chimney for the fault and rectify. The test should be carried out with all windows and doors
closed, if an extractor fan is situated in the room, this test should be repeated with the fan running. If there is a
connected room with an extractor fan, the test should be repeated with all the doors to that room opened and the
extractor fan running.
Demonstrate the lighting and extinguishing procedures to the user.
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The curing effect of heating the coals will cause an initial odour which, although not harmful, may require additional
ventilation until the odour has disappeared.
Any debris or soot is cleaned from the appliance. Advise the customer that they should read their Users Instructions
before operating the fire and always follow the advice in the section headed ‘Removal of Debris or Soot Deposits’.
The appliance must be serviced annually by a competent person in accordance with these instructions and the
appliance is checked for spillage in accordance with the method detailed in these instructions.
Complete the section in the enclosed registration leaflet. Advise that any component part of this appliance be
guaranteed against defective workmanship or faulty materials for a period of twelve months from the date of
purchase.
Any such part will be replaced free of charge on receipt of the purchasers address at the cost of postage only,
provided that:
1. It is accompanied by the registration section cut out of the booklet, together with the original purchase receipt,
which will be returned with the replacement part.
2. A competent person has carried out installation, repairs and/or adjustments, such as the supplier’s representative
or a CORGI registered installer. Page 8

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Allow the appliance to cool sufficiently before removing all of the coals and firebed components for cleaning
purposes. Once all the ceramics are removed from the firebed check that no debris is located in the burner slots
(both front and rear). If any debris is present it may easily be removed by using a small piece of thin cardboard to
ease out any foreign matter. Be sure to remove the cardboard after use. To ensure that the release of fibres from these
RCF articles is kept to a minimum, during installation and servicing we recommend that you use a HEPA filtered
vacuum to remove any dust and soot accumulated in and around the fire before and after working on the fire. When
replacing these articles we recommend that the replaced items are not broken up, but are sealed within heavy duty
polythene bags, clearly labelled as RCF waste. This is not classified as "hazardous waste" and may be disposed of at a
tipping site licensed for the disposal of industrial waste. Protective clothing is not required when handling these
articles, but we recommend you follow the normal hygiene rules of not smoking, eating or drinking in the work area
and always wash your hands before eating or drinking. Any sooty deposit on the thermocouple probe can be cleaned
off using a non-fluffy cloth. DO NOT USE ABRASIVE MATERIALS
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TURN OFF THE GAS SUPPLY TO THE APPLIANCE. Remove coals, coal supports, burner inserts, front
simulated coal and fibre back/side cheek assembly. To gain access to components below the burner assembly it has to
be removed from the vent box case by disconnecting the gas supply at the inlet elbow and unscrewing the two screws
at the base of the facia panel.
I. TO CLEAN OR REPLACE THE INJECTOR: Unscrew the compression nut connecting the gas supply to the
elbow injector while supporting the injector. This is to prevent distortion of the framework, unscrew and
remove the gas supply tube from the gas control valve, hold the injector lock nut with a spanner and rotate the
injector. Replace in reverse order.
II. TO REPLACE THE GAS CONTROL (Tap/FSD): Disconnect the three gas pipes and the thermocouple from
the control. Pull off the knob and lay to one side. Undo the retaining nut at the front of the tap niting
assembly to withdraw control from the mounting bracket. Replace in reverse order.
III. TO REPLACE THE PIEZO IGNITER: Pull off the HT lead from the rear of the igniter, prevent the metal
fixing nut from turning, rotate the body of the igniter to unscrew and withdraw the igniter from the front.
Replace in reverse order and reconnect the HT lead.
IV. TO REPLACE THE OXY-PILOT ASSEMBLY: The operation of the oxy-pilot depends on the proximity of
the spark electrode and the thermocouple tip, if either of these components are defective the assembly must be
replaced. This is achieved by removing the tube nut from the base of the pilot and the thermocouple from the
FSD also the igniter lead and the two M4 screws securing the bracket to the framework. Replace in reverse
order, the spark gap is shown in Fig 18.
Page 9

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For spares contact the manufacturer at the address below.
DESCRIPTION CROSSLEE No GC No
Piezo Igniter 40245 397 686
Oxy-Pilot Burner Assy (SIT) 42313
Control Knob 40232 170 014
Control Valve 42143
Main Injector Stereomatic 42168
Coal Support 42981
Burner Inserts (2) 42952
Front Coal Mould 40481
Set of Coals 42937
Fibre Back Panel 42953
HEAT INPUT
18,500 Btu/h 5.42 kW (GROSS)
________________________________
_
Royal Cozyfires are manufactured by:
CROSSLEE plc
Aber Park Industrial Estate,
Aber Road, Flint, Flintshire. CH6 5EX
Spares Tel [phone]
Fax: [phone]
Service (GSA Ltd) 01703 516611
Customer Service 01422 200660
Fax [phone]
*Technical Help Line 0906 8633268
*Calls charged at 50p per minute