Spartherm XS 500 User manual

GB
Installation and Operating Instructions
Linear Fireplace Cassettes

GB 2
FOREWORD / QUALITY PHILOSOPHY
You have chosen to purchase a Spartherm fireplace cassette – thank you for
the trust you have placed in us.
In a world characterised by an abundance of choice and mass production,
our company name is associated with the principles of our owner Mr. Gerhard
Manfred:
“High technical quality combined with contemporary design and service for the
satisfaction of our customers and to achieve their recommendation.”
In combination with our specialist trade partners, we offer you first-class
products that touch people on an emotional level, creating feelings of security
and comfort. To ensure this is achieved, we recommend that you carefully read
these operating instructions so that you can become quickly and comprehen-
sively acquainted with your fireplace cassette.
Besides information on using the cassette, these instructions also include
important care and operating information for your safety and to maintain the
value of your fireplace cassette, as well as providing you with valuable tips
and assistance. In addition, we will demonstrate how you can operate your
fireplace cassette in an environmentally friendly way.
If you have any further questions, please contact your specialist dealer.
Hoping you enjoy a beautiful fire at all times!
Your Spartherm Team
G.M. Rokossa

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CONTENTS
General information 4
1. Certified quality / definition 5
1.1 Scope of delivery 5
1.2 Transport damage 5
2. Installation instructions 5
2.1 Adjusting the feet of linear fireplace cassettes 6
2.2 Fundamental requirements for the installation/use of an open fireplace6
2.2.1 Installation location 6
2.2.2 Multiple installations 7
2.3 Technical data & dimension sheets 7
2.4 Combustion air supply 10
2.5 Combustion air pipes 10
2.6 Flow restrictors 10
2.7 General requirements for the use of fireplace cassettes in existing
fireplaces 10
2.8 Preparation of the existing fireplace 11
3. Fire protection 11
3.1 Flooring 11
3.2 Thermal radiation field 12
3.3 Load-bearing components made of concrete and reinforced concrete 12
3.4 Special safety measures for protecting adjacent combustible
construction components from fire (when retrofitting the cassette
into a fireplace) 12
3.5 Wooden beams 12
3.6 Heat insulation material 12
3.6.1 Masonry work for walls needing protection 13
3.7 Expansion joint between the casing and the fireplace cassette 13
3.8 Combustion chamber design 13
3.9 Example installation 15
4. Installation 15
4.1 Installation of the fireplace cassette into an existing fireplace 15
4.2 Installing the frame 16
4.3 Aligning the fireplace cassette 17
4.4 Installing or dismantling the firebox into/from the convection air
jacket 17
4.5 Installation of the convection air sockets 18
4.6 Connecting a hot air blower 18
4.7 Dismantling and installing the firebox door 19
4.8 Installing the exhaust gas flue at rear / bottom 20
4.9 Firebox lining 22
5. Operating instructions 23
5.1 General instructions about operation 23
5.2 Type plate 23
5.3 Burning wood 24
5.3.1 First use/commissioning 24
5.3.2 Combustion air regulation 24
5.4 Lighting a fire / burning wood 25
5.4.1 Adding wood / end of the fire 26
5.4.2 Volume of wood to add per hour 26
5.5 Heating output regulation 26
5.6 Room heating capacity 26
5.7 Heating in the transitional period / unfavourable weather conditions 27
5.8 Fuel 27
5.9 CO2- neutrality 28
5.9.1 Storing wood 28
5.9.2 Your contribution to environmental protection 28
5.10 Chimney fire 29

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GENERAL INFORMATION
Spartherm fireplace cassettes are high quality German products. They
are easy to install because they are pre-assembled. Please observe these
instructions and discuss them together with the new owner of the fireplace
cassette. You should talk to the responsible heating inspector/chimney
sweep in your district before installing your fireplace cassette. The inspector
will advise you about the relevant building regulations and the suitability of
your chimney, as well as carrying out the approval process for your fireplace
cassette. The inspection of your chimney will be conducted in accordance
with DIN EN 13384 using the three key values provided in these instructions
(see “Technical data”).
OUR FIREPLACE INSERT HAS BEEN TESTED IN ACCORDANCE WITH DIN
EN 13229 AND SATISFIES THE REQUIREMENTS STIPULATED IN THE
CONSTRUCTION PRODUCTS DIRECTIVE.(DECLARATION OF PERFOR-
MANCE IS AVAILABLE AND CAN BE VIEWED AT WWW.SPARTHERM.
COM).
Small children, old or frail people: As with all heating appliances, it is a
good idea to install safety devices for these groups of people because the
glass panel and also the outer casing of the fireplace cassette can become
very hot! Risk of burning! Never allow these groups of people to touch or
use a fireplace cassette without supervision when a fire is lit or has just
been extinguished! In general, the fireplace cassette should not be operated
without supervision for long periods of time!
National and European standards, relevant country-specific and local regu-
lations and guidelines, as well as the relevant fire regulations in the German
state, are to be observed when installing and operating your fireplace cas-
sette and when connecting it to the chimney.
Negative pressures greater than 20-25 Pa can influence correct operation.
The panel can become increasingly soiled or noise can be intensified!
6. Cleaning and care 29
6.1 Maintenance 30
7. Troubleshooting 30
7.1 Glass experiencing heavy, quick and irregular sooting 30
7.2 Fire is difficult to light 30
7.3 Smoke leakage when adding wood to the fire 31
7.4 Fire burns too quickly / wood consumption is too high 31
8. General warranty terms and conditions 31
8.1 Scope of Application 31
8.2 General information 31
8.3 Warranty period 31
8.4 Requirement of Effectiveness for the Warranty 32
8.5 Warranty exclusions 32
8.6 Defect remediation/repairs 32
8.7 Extension of Warranty 32
8.8 Spare parts 32
8.9 Liability 33
8.10 Note 33

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1. CERTIFIED QUALITY / DEFINITION
Our fireplace cassettes are tested according to DIN 13229.
This family of cassettes can be installed in five standard sizes (500-900)
into, for example, existing open fireplaces. However, it is also possible to
install the fireplace cassette in a similar way to a fireplace insert if the
appropriate tests have been completed. This includes taking into account
the relevant sizes of the air supply and recirculation openings.
The fireplace cassettes have a self-closing firebox door so that the door
is only opened for operating the fireplace (e.g. cleaning the firebox or for
putting more fuel on the fire). It is not permitted to tamper with the closing
mecha-nism for safety reasons and should this occur it will invalidate the
guarantee and the approval to use the fireplace cassette. The guarantee and
the approval to use the fireplace cassette are also invalidated if the cassette
is technically modified in any other area by the customer.
1.1 SCOPE OF DELIVERY
A fireplace cassette with the following characteristics:
• Firebox made of refractory concrete/vermiculite
• Primary and secondary airflow systems
• Self-closing firebox door with a high temperature-resistant ceramic
glass panel
• Heat-resistant gloves
• Type plate (mounting location, see 5.2)
1.2 TRANSPORT DAMAGE
Please immediately check the goods on delivery (visual inspection). Note
any damage that may have occurred on your delivery note and then please
inform your fireplace fitter. Protect the visible parts of the cassette from
soiling or damage during installation.Only approved transport aids with suf-
ficient load-bearing capacity may be used for transporting your fireplace
cassette. The following points must be observed for safe and uncomplicated
transport:
• The fireplace cassette must generally only be transported either in an
upright position or slightly inclined onto its rear!
• If a hand truck is being used as a transport aid, this may only be posi-
tioned at the rear of the cassette.
2. INSTALLATION INSTRUCTIONS
Your fireplace cassette may only be assembled and installed by a specialist
fireplace fitter. You should talk to the responsible heating inspector/chimney
sweep in your district before setting up and installing the fireplace cassette
in order to clarify the suitability of your chimney and installation location, as
well as for any other possible issues.

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2.1 ADJUSTING THE FEET OF LINEAR FIREPLACE
CASSETTES
Your fireplace cassette is delivered with the feet secured by a nut (Fig. 1).
Undo the nut before installation (Fig. 2). You will need a size 19 spanner.
The feet can then be adjusted from the inside during installation of the
fireplace cassette.
2.2 FUNDAMENTAL REQUIREMENTS FOR THE
INSTALLATION/USE OF AN OPEN FIREPLACE
All necessary national and European standards, as well as local regulations
in the German state (DIN, DIN EN, state building regulations, fire regula-
tions etc.) must be observed and applied for the installation, connection
and operation of the fireplace cassette. The following is a list of the relevant
regulations (without any claim to completeness).
FeuVo/LBO/VKF: Fire regulations of the relevant federal state / state
building regulations or fire protection regulations of
the VKF (Switzerland)
2.BlmSchV: First ordinance for implementing the Federal Immis-
sion Control Act
TR-OL: Specialist regulations issued by the Tile Stove and Air
Heating System Association (ZVSHK)
DIN 1298 / EN 1856: Connecting flue pipes for heat generating systems
DIN EN 13229: Inset appliances including open fires using solid fuels
DIN 18896: Fireplaces using solid fuels, technical specifications
for installation and use
DIN EN 13384: Exhaust gas systems calculation method
DIN 18160-1/2: Exhaust gas systems / residential chimneys
Fireplaces may only be installed in rooms and locations where no danger
results from their position, structural conditions and type of use. The sur-
face area of the installation room must be designed in such a way and be
large enough to ensure that the fireplace can be properly operated in line
with its intended purpose.
Fireplace cassettes are fireplaces that are dependent on room air. This
means that problems can arise when a ventilation system is operated at the
same time (e.g. cooker extractor hood, bathroom fan, etc.). In these cases,
suitable measures (e.g. low pressure monitor) must be taken to ensure that
safe operation is guaranteed.
2.2.1 INSTALLATION LOCATION
General requirements placed on installation sites for fireplaces and
fireplace cassettes:
Fireplace cassettes may only be installed in rooms and locations where no
danger results from their position, structural conditions and type of use. In
particular, in the case of fireplace designs dependent on room air then suf-
ficient combustion air must flow through the installation space. The surface
area of the installation room must be designed in such a way and be large
enough to ensure that e.g. open fireplaces with cassettes can be properly
operated.
There is no risk to the operation of fireplace cassettes when:
• The system has safety devices that independently and reliably prevent
low pressure in the installation room.
or
• The total combustion airflow volume required for the fireplace cassettes
Fig. 1 Fig. 2

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and the airflow volume of the ventilation systems do not cause low pres-
sure less than 0.04 mbar in the installation room used for the open
fireplace and any combined rooms providing ventilation.
Fireplace cassettes may not be installed in:
• Stairwells, except in residential buildings with no more than two
apartments.
• Hallways that are generally accessible
• Garages
• Rooms in which highly flammable or explosive materials or mixtures are
processed, stored or manufactured in such volumes that danger may
result from them exploding or becoming inflamed. Fireplace cassettes
may not be installed in rooms or apartments that are vented using venti-
lation systems or hot air heating systems with the aid of fans, unless the
safe operation of the fireplace cassette is guaranteed.
2.2.2 MULTIPLE INSTALLATIONS
It is possible to have multiple installations connected to a chimney in
accordance with DIN 18160 because the fireplace cassettes are fitted with
a self-closing firebox door (A1). All of the fireplaces connected to a chimney
must also have been approved for multiple installations!
2.3 TECHNICAL DATA & DIMENSION SHEETS
The following information has been taken from the testing report and cor-
responds to the testing conditions!
Fireplace
cassette XS 500 S 600 M 700 L 800 XL 900
Technical
data: Unit D4 E4 D5 E5 D6 E7 D8 E10 D11 E 14
Type of fuel: -Firewood
Room thermal
output: kW* 4,0 4,6 4,9 4,9 5,9 6,9 7,9 9,9 10,5 14,0
Wood feed
quantity: kg/h ~ 1,2 ~1,4 ~1,5 ~1,5 ~1,8 ~2,1 ~2,4 ~3,0 ~3,2 ~4,2
Thermal output: kW 4,0-
5,2
4,5-
6,0
4,0-
6,4
4,0-
6,4
4,5-
7,7
4,8-
9
5,5-
10,3
6,9-
12,9
7,4-
13,7
9,8-
15
Efficiency: %* > 80 > 79 > 78
CO-emissions at
13% O2:mg/Nm³ < 1250
Dust emissions: mg/Nm³ < 40
Exhaust gas
temperature at
sockets:
°C 252 335 335 370 360 340 330 360
Manometric
pressure: Pa 12
Exhaust gas
mass flow: g/s 3,8 4,5 5,0 6,5 9,0 10,0 12,0
Combustion air
requirement m³/h 12,6 15,5 16,2 16,6 20,2 26,4 34,3 40,3
Weight depend-
ing on design kg 50 80 95 110 130
Power supply
(only with hot air blower) -230V 50 HZ AC
Requirements:
1. level of BlmSchV. 
2. level of BlmSchV. 
EN 13240 
DIN Plus 
Regensburg 
München 
Aachen 
15a (for Austria) 
Clean Air Ordinance from
01.2011 (for Switzerland) 
* The values given represent the average recorded from multiple fires. These values were recorded under test
conditions without the hot air blower being switched on.

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Linear cassette 600-900 (S, M, L, XL)
Linear cassette XS 500
Dimensions
Linear cassettes
Linear XS
500 (mm)
Linear S
600 (mm)
Linear M
700 (mm)
Linear L
800 (mm)
Linear XL
900 (mm)
Aaperture standard:
45mm aperture standard: 60mm
B456 453 503 523 543
C492 489 539 559 579
D582 609 659 679 699
E345 510 610 710 810
F380 546 646 746 846
G470 666 766 866 966
HØ 130 Ø 150 Ø 150 Ø 150 Ø 150
I352 412 442 472 502
JØ 100 convection air openings: Ø 125
Dimensions
Linear cassettes
Linear XS
500 (mm)
Linear S
600 (mm)
Linear M
700 (mm)
Linear L
800 (mm)
Linear XL
900 (mm)
K400 566 666 766 866
L250 374 434 534 634
M523 520 570 590 610
N405 582 685 782 882
O541 540 590 610 630
P - optional exhaust floor sheet*
Q - optional combustion air spigot behind*
R - optional fan*
S - optional case for speed controller*
T - Optional combustion air spigot below*
* *only for linear cassettes S, M, L and XL
Edge-folding
Edge-folding
Edge-folding
Edge-folding

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Linear cassette XS 500 Linear cassette 600-900 (S,M,L,XL)
1Cassette frame 45, 60, 80 mm
2Firebox door with ceramic glass
3Firebox lining
4Firebox
5Exhaust gas socket
6Convection air jacket
7Optional convection air sockets (Ø100mm)
1Cassette frame 60, 80, 100 mm
2Firebox door with ceramic glass
3Firebox lining
4Firebox
5Inspection/maintenance openings
6Exhaust gas sockets, rotatable (vertically or horizontally)
7Convection air jacket
8Optional convection air sockets (Ø125mm)
9Combustion air sockets, outlet to rear
10 Combustion air sockets, outlet below
11 Hot air blower (speed adjustable)

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2.4 COMBUSTION AIR SUPPLY
Fireplace cassettes may only be installed in rooms with at least one door
to the outside or a window that can be opened or are directly or indirectly
linked to a combustion air supply in other rooms. When the cassettes are
installed in apartments or other functional units then only those rooms in
the same apartment or functional unit may be counted as being linked for
combustion air supply purposes.
2.5 COMBUSTION AIR PIPES
According to the state building regulations - which correspond to Article
37, Paragraph 2 of the Model Building Regulations - combustion air pipes
in buildings with more than two full floors and those pipes that bridge fire
walls must be constructed in such a way that fire and smoke cannot be
transferred to other floors or fire compartments.
PLEASE NOTE: The guidelines for fire protection requirements in ventilation
systems (draft template) – version January 1984 – can be used to show how
the previously named regulations can be fulfilled.
2.6 FLOW RESTRICTORS
Flow restrictors may only be installed in exhaust gas sockets or in flue
pipes. Flow restrictors must be easy to operate. They must have openings in
the form of circular sections, which have a continuous area not less than 3%
of the cross-sectional area, and be at least 20 cm2in size. The setting of the
flow restrictor must be identifiable by the position of the operating handle.
2.7 GENERAL REQUIREMENTS FOR THE USE OF
FIREPLACE CASSETTES IN EXISTING FIREPLACES
The fireplace cassettes are suitable, amongst other things, for retrofitting
into existing fireplaces. Please observe the following installation instruc-
tions before installing the fireplace cassette (read the instructions before
starting the installation of the fireplace cassette and then observe the
instructions during installation):
• Please inform the responsible heating inspector/chimney sweep in your
district before installation.
• The existing open fireplace into which the fireplace cassette is to be
installed must correspond to the guidelines for the construction of fire-
places and the regulations in DIN EN 13229.
• The fitter must satisfy themselves as to what extent the open fire-place
corresponds to these requirements. If necessary, the fitter must carry
out any required corrective work.
• It must be ensured that the flue pipes, exhaust gas collection chamber
and chimney are operationally safe and fireproof.
• Open fireplaces that are retrofitted with a fireplace cassette must have
their own chimney.
• Open fireplaces may only be installed in rooms and locations where no
danger results from their position and structural conditions.
• The installation room must have sufficient combustion air flow.
• The surface area of the installation room must be designed in such a
way and be large enough to ensure that the fireplace can be properly
operated.
FIREPLACE CASSETTES MUST BE INSTALLED BY SPECIALIST FITTERS OR
SPECIALIST COMPANIES.

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2.8 PREPARATION OF THE EXISTING FIREPLACE
• Approval must be obtained from the heating inspector/chimney sweep
for your district before the cassette is installed.
• The chimney must be swept, examined and tested for leaks.
• Check whether the open fireplace is suitable for installing a fireplace
cassette.
• Please note that the fireplace will be subjected to a higher level of stress
after the cassette has been installed.
• The existing open fireplace will be reduced in size due to the installation
of necessary thermal insulation coatings.
IMPORTANT: Take into account the following conditions when measuring up
for the fireplace cassette.
• Shut-off dampers are to be completely opened in the exhaust gas sys-
tem and locked in place so that they cannot close. If required, they are
to be totally removed.
• The combustion air feed pipes that lead to the fireplace must not be
closed. Ensure that there is sufficient combustion air (minimum 360 m³
per hour and m² of the firebox opening).
• The fireplace cassette can be connected to a flexible exhaust gas flue,
which is fed through the existing chimney flue. This flexible exhaust gas
flue must correspond to DIN 1856-T2. (Manufacturer e.g.: Westaflex,
type: MS-System or Haflex, type: 870s)
3. FIRE PROTECTION
3.1 FLOORING
In front of the openings to fireplaces with closed fireboxes, flooring made
out of combustible materials must be protected by a covering of non-
combustible materials. The covering must extend outwards at the front by a
minimum of 500 mm and at the sides by at least 300 mm from the fireplace
opening (see Fig. 3).
The non-combustible covering can be made out of ceramics (e.g. tiles, flag-
stones), natural stone or other mineral construction materials (e.g. marble,
granite), metal with a thickness of at least 1mm or glass of corresponding
strength. The covering must be secured against dislocation.
A B
XS 500
Floor covering
466 mm
S 600 566 mm
M 700 666 mm
L 800 766 mm
XL 900 866 mm
Fig.3

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3.4 SPECIAL SAFETY MEASURES FOR PROTECT-
ING ADJACENT COMBUSTIBLE CONSTRUCTION
COMPONENTS FROM FIRE (WHEN RETROFITTING
THE CASSETTE INTO A FIREPLACE)
1. There must be a distance of at least 50 mm between built-in furniture
and the fireplace casing.
2. In the case of construction elements that only border small areas of the
cassette (wall, floor or ceiling coverings), it is recommended that you
maintain a distance of 10 mm.
3.5 WOODEN BEAMS
Wooden beams must not be fitted in the fireplace’s thermal radiation field.
Any wooden beams above a fireplace must be completely ventilated on all
sides by a minimum of 10 mm. Directly fixing them to thermal bridges is
not allowed.
3.6 HEAT INSULATION MATERIAL
Heat insulation materials are only required when the adjacent construction
components of the building / fireplace location etc. need to be protected
against “high” temperatures. This is the case for combustible and load-
bearing construction components. The insulation thicknesses listed are
based on the reference insulation material rock wool according to AGI-Q
132. Silicon-based insulation material can also be used with the relevant
building approvals. These materials enable a significant reduction in the
insulation thickness (e.g. Silka type: 250 KM)
3.2 THERMAL RADIATION FIELD
No combustible construction components, furniture, curtains or decoration
may be placed within a distance of 800 mm (see Fig. 4) of the firebox door
in the thermal radiation field. This distance can be reduced to 400 mm when
a ventilated radiation protection plate is installed between the fireplace and
the combustible elements. No combustible objects may be placed within a
distance of 500 mm above the fireplace.
3.3 LOAD-BEARING COMPONENTS MADE OF CON-
CRETE AND REINFORCED CONCRETE
The fireplace cassette is to be installed in such a way that no load-bearing
construction components made out of concrete or reinforced concrete are
located at the side of the outlet points for the hot air within a distance of
500 mm at the front and up to a height of 50 mm above the outlet points
for the convection air.
Abb.4

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3.6.1 MASONRY WORK FOR WALLS NEEDING
PROTECTION
• When installing the open fireplace on walls needing protection then
masonry work is required. The masonry work must project at least 200
mm above the flue pipes.
• The masonry work (100 mm) can be dispensed with when the build-
ing’s alls are:
- At least 115 mm thick
- Made of non-combustible construction components
- Not made of load-bearing concrete or reinforced concrete
• The masonry work can be completed in a conventional way e.g. using
bricks or can also be constructed out of so-called “thermal insulation
panels” so that the overall construction depth - consisting of masonry
work and thermal insulation - can be significantly reduced. Alternatively,
the masonry work and the insulation can be completed using suitable
insulation materials, see 3.6. This will enable the overall thickness to be
reduced significantly.
3.7 EXPANSION JOINT BETWEEN THE CASING AND
THE FIREPLACE CASSETTE
There must be no direct connection between the fireplace cassette and the
casing. An expansion joint is to be fitted that should be connected using e.g.
a sealing strip. Please note that there must be a minimum distance of 6 mm
between the door frame and the fireplace apron to enable the firebox door
to be dismantled if required.
3.8 COMBUSTION CHAMBER DESIGN
Design A
No recirculating or primary air cross section openings need to be produced.
Combustion chamber spacings
Linear cassette Setup floor Mounting wall Ceiling Side wall
XS 500 40 mm 60 mm 200 mm 60 mm
S 600 40 mm 10 mm 200 mm 10 mm
M 700 40 mm 10 mm 200 mm 10 mm
L 800 40 mm 10 mm 200 mm 10 mm
XL 900 40 mm 10 mm 200 mm 10 mm
Rock wool mats to AGI Q-132)
Linear cassette Setup floor Mounting wall Ceiling Side wall
XS 500 0 mm 50 mm 50 mm 60 mm
S 600 0 mm 200 mm 190 mm 170 mm
M 700 0 mm 200 mm 190 mm 170 mm
L 800 0 mm 200 mm 190 mm 180 mm
XL 900 0 mm 200 mm 170 mm 180 mm

GB 14
Design B
Inlet and recirculating air apertures must be created in the fireplace. At
least 50% of all indicated openings must not be closable.
Linear cassette XS 500 S 600 M 700 L 800 XL 900
Recirculating air
openings in cm² 220 400 400 640 880
Primary air
openings in cm² 450 450 450 730 960
Combustion chamber spacings
Linear cassette Setup floor Mounting wall Ceiling Side wall
XS 500 40 mm 60 mm 200 mm 60 mm
S 600 40 mm 60 mm 200 mm 60 mm
M 700 40 mm 60 mm 200 mm 60 mm
L 800 40 mm 60 mm 200 mm 60 mm
XL 900 40 mm 60 mm 200 mm 60 mm
Rock wool mats to AGI Q-132)
Linear cassette Setup floor Mounting wall Ceiling Side wall
XS 500 0 mm 50 mm 50 mm 60 mm
S 600 0 mm 160 mm 120 mm 80 mm
M 700 0 mm 150 mm 110 mm 90 mm
L 800 0 mm 150 mm 130 mm 90 mm
XL 900 0 mm 140 mm 130 mm 70 mm
The distance between the fireplace cassette and the insulation must be 60
mm all the way around the fireplace cassette. Insofar as the adjacent con-
struction components are not combustible or load-bearing then the distance
can be reduced to 10 mm. The heat insulation thicknesses are valid for hot
air systems.
Installation situation Installation situation A
Installation situation Installation situation B

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3.9 EXAMPLE INSTALLATION
AFireplace cassette
BInsulation
CMasonry work
DWall made of combustible materials/components or load-bearing walls
EConvection air pipe
E1 = 10mm (distance if an adjacent construction component has no requirements)
E2 = 60mm (distance to combustible construction materials)
FCeiling made of combustible construction materials or combustible construction components
GCasing
HFlooring made out of non-combustible construction materials
Fig.5
Fig.6
4. INSTALLATION
4.1 INSTALLATION OF THE FIREPLACE CASSETTE
INTO AN EXISTING FIREPLACE
• Clean the firebox in the existing open fireplace thoroughly.
• Installation measures that bring about any restriction to the open fire-
place and reduce safety are not permitted.
• Check whether the flooring of the existing fireplace is level. Slight
unevenness can be balanced out later via the adjustable feet using an
Allen key.
• The prescribed minimum thermal insulation for the whole fireplace - cal-
culated according to DIN EN 13229 - must be adhered to if the existing
open fireplace was not expertly constructed.
• In order to prevent fires and deflagration, it is important to ensure that
there are no dangerous deposits in the exhaust gas collection chamber.
These critical areas must be constructed in such a way that soot parti-
cles and flying ash can fall back into the firebox. This can be achieved
using deflectors or through corresponding lining with fire-clay or refrac-
tory concrete. Access is made possible through the cleaning openings.
• Install the exhaust gas flue system in the existing chimney. This must
be a flexible system according to DIN EN 1856-T2 but it may vary from
country to country. Attention: The fireplace cassette has not yet been
fitted at this stage! The required process steps for connecting the flex-
ible exhaust gas flue system to the exhaust gas socket on the fireplace
cassette are listed here:
- Dismantle the deflector plate by firstly removing both of the side blocks
of the firebox lining.
- Loosen the two screws securing the exhaust gas connection and place
it laterally into the combustion chamber (Fig. 7).
- Now remove the exhaust gas socket from the fireplace cassette and
connect this socket to the flexible exhaust gas pipe inside the open
fireplace. The linear measurement of the flexible exhaust gas pipe
should be the actual length required so that the flexible pipe cannot be

GB 16
pushed into any gaps.
- Then insert the complete fireplace cassette into the open fire-place
and reach through the open exhaust gas connection on the cassette
into the fireplace. Pull the exhaust gas socket onto the rear wall of the
cassette and fix it in place with two screws and nuts via the firebox.
• Replace the deflector plate and straighten up the fireplace cassette
where necessary.
• After the fireplace cassette has been installed, the space between the
outer casing of the cassette and the walls of the open fireplace must
be tightly filled in.
• All remaining unfilled (non-airtight) areas - through which “false air” can
enter - are to be sealed using a sealing agent (e.g. rock wool and, where
required, a sheet metal cover).
• Any existing wooden beams in the open fireplace are to be protected
using additional thermal protection (e.g. air deflector plate) when they
are within the thermal radiation field or are located in the area of the
cassette’s thermal air convection field. This is particularly important
when the fireplace cassette protrudes out of the existing open fire-place.
• The changes to the thermal radiation field when using the fireplace cas-
sette in comparison to that of the open fireplace should be taken into
account.
4.2 INSTALLING THE FRAME
In order to install / dismantle the cassette frame, the firebox door needs to
be opened to access the four fastening screws for the frame. The screws
must be turned approx 3-4 times to loosen them. The frame can then be
removed in a forwards direction. Installation is carried out in the reverse
order.
In cassette designs including a hot air blower, it is necessary to initially
remove the rotary knob at the front and unscrew the nut. The speed control-
ler remains in position within the hole.
A = Loosen the screws in the firebox
Fig.7
Fig.8

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4.3 ALIGNING THE FIREPLACE CASSETTE
In order to align the fireplace cassette, the
four feet can be adjusted from the side,
front or rear using a spanner to ensure that
the frame / firebox are level.
If it is necessary to align the fireplace cas-
sette at a later date then it is possible to
gain access to the feet through the firebox itself. This involves dismantling
the firebox lining and setting the adjustment screws with a 6 mm Allen key.
(Not valid for linear cassette XS 500).
Green arrow (1):
Height adjustment of the foot on the
convection air jacket.
Red arrow: (2)
Height adjustment of the firebox in
the convection air jacket
Blue arrow: (3)
Locking the firebox in position in
the convection air jacket (transport
locking device). These must always
be released if the combustion
chamber needs to be aligned.
Yellow arrow: (4)
Positioning rectangle
If new settings have been made then it is necessary to reinsert the floor
insulation because this guarantees that the holes are insulated from the
room’s air.
4.4 INSTALLING OR DISMANTLING THE FIREBOX
INTO/FROM THE CONVECTION AIR JACKET
The firebox can be dismantled from the convection air jacket in its installed
state. Reasons for this include e.g. the retrofitting of a hot air blower. How-
ever, the prerequisite for this is that the combustion air pipe is not fixed at
the rear of the cassette or that it allows sufficient movement of the firebox
in a forwards direction.
Process steps:
1. Dismantle the cassette frame (see 4.2).
2. Remove the firebox lining (see 4.9).
3. Loosen the firebox locking mechanism (blue arrow, 3)
4. Turn the adjustment screws in the firebox (red arrow, 2) until they are
visible in the firebox.
5. Take the firebox door off its hinges (see 4.7).
6. Lift the firebox at the front using 1-2 persons and remove it in a for-
wards direction. The positioning rectangle (yellow arrow, see 2.16) must
no longer be locked in the opening, only then is it possible to move the
fireplace cassette!
PLEASE NOTE: The firebox must be lifted into the convection air jacket
because the firebox’s feet can otherwise cause scratches to the convection
air jacket.
Installation is carried out in the reverse order!
1
1
2
2
3
4

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4.5 INSTALLATION OF THE CONVECTION AIR
SOCKETS
In order to install the circulation pipes (convection air), initially break out the
dummy covers and then screw on the two sockets as shown (see Fig. 9a)
using the self-tapping screws provided. Alternatively, these screws can be
screwed from the inside of the convection air jacket out-wards. In order to
redirect the airflow volume, the flaps on the flow control covers at the top
front of the convection air jacket need to be pushed into the cut-out slots
(see Fig. 9b).
To alter the airflow in the pipework, the size of the baffle plate at the nomi-
nal failure point can be reduced.
Bend when breaking: corresponds to approx. 50% airflow vol-
ume via the connected pipe system and
approx. 50% in the installation room.
Without any changes: corresponds to approx 70 % airflow vol-
ume via the connected pipe system and
approx. 30% in the installation room.
4.6 CONNECTING A HOT AIR BLOWER
Not valid for linear cassette XS 500!
If the fireplace cassette has been ordered with a hot air blower then you
only need to connect the plug to a properly earthed electricity socket. The
following steps should be carried out for maintenance / inspection of the
hot air blower:
1. Dismantle the cover (see 4.2)
2. Remove the firebox door (see 4.7)
3. Remove the firebox lining (see 4.9)
4. The blower is accessible after the
inclined rear wall has been dismantled.
In order to retrofit a hot air blower, carry out the previously described steps
numbered 1 to 3 and continue with steps 4b to 4g.
4b. Remove the firebox
4c. Installing the hot air blower involves the following components:
- connection cable set, blower cable, speed regulator, cylindrical fan
and cable gland, Temperature sensor
4d. Cut out the pre-cut section of the convection air jacket on the lower
left side using a hand saw. The metal plate can then be broken out of
the convection air jacket. The speed regulator will be positioned in this
section at a later stage.
4e. Now assemble the blower onto the
fixing bracket (see picture) and install
it at the middle / bottom of the convec-
tion air jacket.
4f. In addition, attach the temperature
sensor provided to the blower bracket. Attach the temperature sensor here
Predetermined breaking point, pre-stressed
Fig.9a Abb.9b

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4g. Connect the cable wires to the terminals on the blower as shown and
to the control box for the speed regulator.
After the cables have been connected, check and ensure proper function-
ality before finishing the installation. The cables must be fixed using the
holding flaps. The flaps can either by pressed in from the outside or levered
out from the inside. Once the cable has been pushed under the flaps, the
flaps must then be pushed down lightly onto the cable.
PLEASE NOTE: Do not press on the flaps too hard because otherwise the
cable could become damaged!
4h. Pull the rubber knob off the front of the control shaft and twist off the
nut and ring washer. The control shaft is inserted through two holes in
the frame when installing the frame. It may be necessary to order a
new cassette frame if the existing one does not have any corresponding
holes
4.7 DISMANTLING AND INSTALLING THE FIREBOX
DOOR
Please follow the following steps to dismantle / install the firebox door.
Take care when carrying out these tasks as otherwise damage to the casing
/ door cannot be ruled out. We recommend protecting the casing / metal
plates with an overlay.
Dismantling:
1. Use a screwdriver or a similar tool to
remove the safety clasp on the stop-per
side (hinge side) of the door.
2. Swing the door open. Then tighten the
Allen screw on the lower hinge with a 3
mm Allen key.
3. Take hold of the door at the bottom.
Raise the door a little with a light lifting
movement so that the lower pin of the
hinge is exposed.
Blower connection cable Mains supply

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4. In this position, pull the door a little
forward at the bottom.
5. Now allow the door to drop down a little
so that it comes away from the upper
guidance pin and can be removed.
The door is now free and can be carefully placed to one side.
INSTALLATION: Installation is carried out in the reverse order:
1. Firstly guide the door in a slightly
inclined position onto the fixture for the
hinge side of the door. In the process,
support the door from below so that the
fireplace casing is not scratched.
2. Then swing the door inwards and set
the lower pin into the lower fixture. To
ensure the hexagonal socket can slide
into the fixture, move the door a little
(swivel the door).
3. Loosen the hexagonal socket on the
lower hinge with a 3 mm Allen key.
4. Close the door and then push the
safety clasp back onto the pin.
4.8 INSTALLING THE EXHAUST GAS FLUE AT REAR /
BOTTOM
Not valid for linear cassette XS 500!
Exhaust gas connection at rear:
The connection for the exhaust gas flue in a horizontal direction at the rear
is realised as described below:
1. Break off the dummy cover on the
convection air jacket and the firebox at
the rear of the appliance by twisting it
frequently.
2. Connect the 125 mm or 150 mm exhaust air sockets with a binding
clamp to the exhaust gas flue. Then screw the sockets to the rear wall
of the firebox using three screws.
3. Place the rear wall cover around the
exhaust gas flue and fix it in place using
the fixing screws.