Stanley Cara User manual

Cara+ Solid Fuel
High Output Boiler
Insert Stove
PLEASE RETAIN
This appliance is hot while in operation and retains its heat for a long period of time after use. Children,
aged or infirm persons should be supervised at all times and should not be allowed to touch the hot
working surfaces while in use or until the appliance has thoroughly cooled.
When using the stove in situations where children, aged and/or infirm persons are present a fireguard
must be used to prevent accidental contact with the stove. The fireguard should be
manufactured in accordance with BS 8423:2010.
INSTALLATION AND OPERATING INSTRUCTIONS

TABLE OF CONTENTS
PAGE NO.
1. Stanley Solid Fuel Stove Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Important Operation/ Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4. Installation & Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Flues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8. Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9. Fitting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10. Front Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11. Down Draughts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
12. Ventilation and Combustion Air Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13. External Ducted Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
14. Heat Recovery Ventilation (HRV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
15. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
16. Clearances To Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
17. Floor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
18. Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
19. Pipe Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
20. Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
21. Gravity Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
22. Injector Tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
23. Water Circuit Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
24. Flue & Water Pipe Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
25. Stove Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
26. Commissioning and Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
27. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
28. Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
29. Recommended Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
30. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
31. Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32. Lighting The Stove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
33. Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
34. Slow Burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
35. De-Ashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
36. Disposal of Ashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
37. Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
38. Grate Removal and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1

PAGE NO.
39. Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
40. Adjust The Door Catch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
41. Chimney Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
42. Glass Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
43. Vitreous Enamel Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
44. Cleaning A Matt Black/ Senotherm Stove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
45. Prolonged Periods of Non Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
46. Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
47. Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
48. CO Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
49. Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
50. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
51. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2

STANLEY SOLID FUEL STOVE WARRANTY
CONDITIONS OF WARRANTY
Your Stanley Solid Fuel Stove is guaranteed against any part that fails (under normal operating conditions) as detailed
in the following table with timelines specified from the date of installation of the appliance. If the unit is not installed with-
in six months of date of purchase, the warranty will commence six months from the date of purchase.
Warranty Period Parts Covered (Parts & Labour unless Stated)
Up to 1 Year • Refractory materials (supply only)
• Rope seals, glass seals and cement seals.
• Surface Finish on Seno models.
• Grates and fire bars.
• Ceramic glass is covered for Thermal breakage (supply only).
• Rust (if reported before installation)
• Aesthetic Damage (provided reported on date of receipt)
Up to 5 Years • All external castings & enamel finishes (excluding impact damage or
damage caused by overfiring). Pictures of damage must be submitted to
WS Service Department.
Up to 3 Years • Boiler - A Leaking Boiler Report must be conducted by an Authorised
Stanley Service Engineer and submitted to WS Service Department for
review.
All warranty claims must be reported to the Waterford Stanley Service Department and must be submitted with the prod-
uct serial number (located on the front casting), date of purchase, proof of purchase (if requested) and details of the
specific nature of the problem.
The warranty is given only to the original consumer/purchaser only and is non- transferable. The appliance must be
installed by a suitable qualified person and installed as per the requirements of the manual. Failure to comply with the
Installation requirements or Building Regulations will void your warranty. Waterford Stanley reserve the right to replace
any part due to manufacturing defect that fails within the warranty period under the terms of the warranty. The unit must
be used for normal domestic purposes only and in accordance with manufacturer's operation instructions.
LIMITS OF LIABILITY
The warranty does not cover:
* Special, incidental or consequential damages, injury to persons or Property, or any other consequential loss.
* Any issue caused by negligence, misuse, abuse or circumstances beyond Waterford Stanley’s control.
* Any issue with wear and tear, modification, alteration, or servicing by anyone other than an authorized service
engineer.
* Installation and operational related problems such as draught related issues external to the stove, inadequate
venting or ventilation, excessive flue offsets, negative air pressure caused by insufficient burning of improper
fuel.
* Damage caused to the unit while in transit.
* Enamel discolouration due to over firing, enamel damage caused by impact, damage to baffles caused by
over firing and fading of surface finish on casting.
* Stress fractures on bricks.
* Rust on cast iron parts unless reported prior to unit being installed.
* Aesthetic damage, rust & missing parts on units purchased off display.
Note: Adequate clearance must be maintained around the appliance to ensure the ease of part removal in the possi-
ble event of their damage/failure. Waterford Stanley are not responsible for any costs incurred in the removal of items
installed in the vicinity of the appliance that have to be moved to facilitate a part replacement.
3

INSTALLATION CHECK LIST
Tick
Flue System
1. Minimum Flue Height of 4.6 metres (15 feet).
2. Appliance should be connected to a 125mm (5”) flue pipe within a metre and then
the flue size increased to a minimum of 150mm (6”) diameter.
3. The horizontal flue run should not exceed 150mm (6”)
4. All flue pipework passing through walls must be sleeved & adequately insulated in line
with current Building Regulations.
5. Appliance should be connected to a chimney of less than 200mm (8”) in diameter
(otherwise the chimney must be lined with a 6” flue liner).
6. The chimney/ flue termination must be located in accordance with building regulations part J.
7. The chimney serving this appliance should not serve any other appliance.
8. Access should be provided to the chimney serving the appliance to allow for cleaning.
9. It is a requirement by Building Regulations to have a carbon monoxide alarm
fitted to any room with a solid fuel appliance.
Location
10. Clearance to combustible materials must be adhered to as described in the Clearance
to Combustible section.
11. The stove must be installed on a floor protector that covers the area under the stove
and extends 14” to the front and 6” to the sides.
12. Clearance must be maintained to allow for maintenance and part replacement.
Ventilation & Combustion Air Requirements
13. The room in which the appliance is located should have an air vent of adequate size to
support correct combustion (see Ventilation & Combustion Air Requirement Section for
specific details).
14. The stove must not be installed in the same room as an extractor fan.
Plumbing and Electrical Requirements
15. All plumbing and electrical work associated with the appliance must be conducted in accor-
dance with current Building Regulations, Maintenance Instructions and Best Practice Guidelines.
4

IMPORTANT OPERATION / MAINTENANCE NOTES
Now that your Stanley Solid Fuel Stove is installed and no doubt you are looking forward to many comforts it
will provide, we would like to give you some tips on how to get the best results from your stove.
1. We would like if you could take some time to read the operating instructions/hints, which we are
confident, will be of great benefit to you.
2. Do not burn fuel with a high moisture content, such as a damp peat or unseasoned timber. This will
only result in a build up of tar in the stove and in the chimney.
3. IMPORTANT: The first few fires should be relatively small to permit the refractory to set properly
and season the stove. During these firings it is recommended to ventilate the room as an
unpleasant (not toxic) odour may be emitted as the paint is completing curement.
4. Inspect the flue-ways of the stove weekly and ensure that there are no blockages. Check flue
ways before lighting especially after a shut down period. Please see chimney cleaning section.
5. Before loading fresh fuel into the firebox, riddle fully to remove all ashes. This will allow better and
cleaner burning. See Re-Fuelling section.
6. Never allow a build up of ashes in the ash pan, as this will cause the grate to burn out prematurely.
Empty the ashpan when refuelling.
7. Avoid slow burning of damp or unseasoned fuel as this will result in tarring flue ways and chim-
ney i.e. peat or timber.
8. Allow adequate air ventilation to ensure plenty of air for combustion.
9. Do not burn rubbish/household plastic.
10. Clean the chimney at least twice a year.
11. Burning soft fuels such as timber and peat will stain the glass. Regular cleaning will prevent
permanent staining. Clean with soapy water when cool.
12. Keep all combustible materials a safe distance away from unit, please see section for clearances
to combustibles.
13. Never use aerosol spray near the appliance when it is in operation.
14. For safety reasons never leave children or the elderly unaccompanied while stove is in use. Use a
fire guard.
15. Avoid contact with the appliance when in use as stove reaches very high operating temperatures.
16. This appliance should be regularly maintained by a competent service engineer.
FUEL CALORIFIC VALUES - SOLID FUELS
Anthracite 25-50mm C.V.: 8.2kW/Kg 14,000 BTUs/lb
House Coal 25-75mm C.V.: 7.2kW/Kg 12,000 BTUs/lb
Timber - Firebox size C.V.: 5.0kW/Kg 8,600 BTUs/lb
Peat Briquettes C.V.: 4.8kW/Kg 8,300 BTUs/lb
5

6
THE CARA+ SOLID FUEL BOILER STOVE
INSTALLATION & OPERATING INSTRUCTIONS
GENERAL
When installing, operating and maintaining your
Cara + Stove, respect basic standards of fire safety.
Read these instructions carefully before commenc-
ing the installation. Failure to do so may result in
damage to persons and property. Consult your local
Municipal office and your insurance representative
to determine what regulations are in force. Save
these instructions for future reference.
Please note that it is a legal requirement under
England & Wales Building Regulations that the
installation of the stove is either carried out under
Local Authority Building Control approval or is
installed by a Competent Person registered with a
Government approved Competent Persons
Scheme. HETAS Ltd operate such a scheme and a
listing of their Registered Competent Persons can
be found on their website at www.hetas.co.uk.
Special care must be taken when installing the stove
such that the requirements of the Health & Safety at
Work Act are met.
Handling
Adequate facilities must be available for loading,
unloading and site handling.
Fire Cement
Some types of fire cement are caustic and should
not be allowed to come into contact with the skin. In
case of contact with the skin wash immediately with
plenty of water.
Asbestos
This stove contains no asbestos. If there is a possi-
bility of disturbing any asbestos in the course of
installation then please seek specialist guidance and
use appropriate protective equipment.
Metal Parts
When installing or servicing this stove care should
be taken to avoid the possibility of personal injury.
“IMPORTANT WARNING”
This stove must not be installed into a chimney that
serves any other heating appliance.
The complete installation must be done in accor-
dance with current Standards and Local Codes. It
should be noted that the requirements and these
publications may be superseded during the life of
this manual.
Please refer to the current standards, BS EN 15287-
1:2007 Design, Installation and Commissioning of
chimneys. BS EN 14336:2004: Heating Systems in
Buildings. Installation & Commissioning of Water
Based Heating Systems. BS EN 12828: 2003;
Heating Systems in Buildings. Design of Water
Based Heating Systems. BS EN 12831: 2003;
Heating Systems in Buildings. method for
calculation of the design heat load.
Your Cara + stove is supplied with the following
items:
• Handle Assembly (See Fig. 1)
• Ashpan
• Operating Tool
• Glove
• Touch-Up Paint (Enamel Only)
• Flue Collar Grub Screw
• Clay Adaptor
• Rigid Pipe
•15
oAdaptor
Fig.1
Nylon Cap Washer
Spindle
Spring Handle
Increasing Collar
End Cap
ELECTRICAL CONNECTIONS
The installation of any electrical services during the
installation of this stove must be carried out by a
registered competent electrician and in accordance
with the requirements of the latest issue of BS 7671.

FLUES
Flues should be vertical wherever possible and
where a bend is necessary, it should not make an
angle of more than 45owith the vertical. Horizontal
flue runs should be avoided in order to minimise flue
resistance and to make sweeping easier it is recom-
mended to use 2 x 45obends rather than a 90o
bend.
CHIMNEY
Do not connect to a chimney serving another
appliance.
The stove is a radiant room heater and must be con-
nected to a chimney of the proper size and type.
The chimney must have a cross-sectional area of at
least 30 square inches 19350sq. mm or a diameter
of at least 6” (150mm). It is best to connect to a
chimney of the same size, as connection to a larger
size may result in a somewhat less draught.
A flue that has proved to be unsatisfactory, particu-
larly with regard to down draught should not be used
for venting this appliance until it has been examined
and any faults corrected. An existing masonry chim-
ney should be inspected and if necessary repaired
by a competent mason or relined using an approved
lining system.
The stove must be connected to a chimney with a
minimum continuous draught of 0.06” w.g. Poor
draught conditions will result in poor performance.
All register plates, restrictor plates, damper etc.,
which could obstruct the flue at a future date should
be removed before connecting this appliance.
If connecting to an existing chimney with a flue
diameter of more that 8” it is recommend to line the
flue using a suitable stainless steel flue liner.
Where a masonry chimney is not available a propri-
etary type of 6”/150mm - twin wall, fully insulated
pipe may be used.
A chimney / flue termination must be located to min-
imise wind effects, a basic guide is that the distance
from the termination to the roof should be at be at
least 2300mm when measured horizontally and at
least 1000mm when measured vertically, (see
Fig.2). In circumstances where there are adjoining
buildings/ structures/ roof openings there are addi-
tional requirements, please refer to building regula-
tions part J.
Fig.2
2300
Fit
appliance
back into
wall
1000
The liner should be approved for use with solid
fuel. (See Fig. 3)
Fig.3
7

8
5” - 8”
Adaptor/
Closure Plate
Fig.4
FITTING INSTRUCTIONS
Step 1
Prepare the fireplace area. Ensure the opening is
suitable for fitting of the insert stove opening
required, i.e. remove fire surround trim if fitted. See
Fig.5.
Fig.5
405mm - 455mm
240mm - 320mm
550mm - 575mm
Min 380mm
Step 4
Remove all internal parts as per pre-assembly
instructions prior to lifting it.
Step 5
Inset the stove to its final position.
USING CLOSURE PLATE - (Skip to Step 10)
Step 6
Drop the 150mm twin wall flexi flue liner down
through the chimney and into the stove.
Step 7
Lay the sealing gasket on to the flue spigot, connect
the flue spigot to the flexi pipe using a 5” extension
pipe and a 5” - 6” adaptor. It is not recommended to
fit a flexi flue liner within 600mm of the stove flue
spigot.
Step 8
Pull the flexi liner back up through the flue outlet and
fix the flue spigot into position using the M8 bolts
provided. It may be necessary to cut a prop to hold
the spigot in place while the fixings are being
attached.
Step 9
Complete the installation of the flexi liner at the top
of the chimney in accordance with the manufactur-
ers instructions.
USING FLEXIBLE LINER - (Skip to Step 16)
Step 2
Ensure the floor area is level with the hearth, this
area needs to be level as the insert fire is screw
fixed to the floor.
Step 3
Decide which boiler tappings are to be used to con-
nect the boiler. Remove the temporary plugs from
the other two connections and replace with perma-
nent boiler plugs.
Fig.6 Chimney Connectors
Offset Adaptor Extension Pipe 15 degree Adaptor
Step 10
Measure the distance to the flue outlet of the stove
and compare to the chimney, decide on best orien-
tation of the offset adaptor.
Step 11
Push the offset adaptor into position and make a
seal using approved fire cement between the adap-
tor and the clay liner. The seal should be tapered to
allow any condensation that may occur in the
chimney flow back into the flue. See Fig.7.

Fig.7
Step 15
Bolt the spigot to the stove and re-apply fire cement
to the seals where it may have been disturbed dur-
ing the installation.
Step 16
Replace the baffle by inserting it at an angle into the
stove as shown in Fig.8. Then lift the baffle up into
the top of the stove while maintaining it at an angle.
Twist the baffle so that it is above the support rail.
Then lift the back edge and slide the baffle back to
the rear of the stove so that the tab on the baffle
drops into the corresponding slot on the support rail.
Step 12
Measure and cut the extension pipe at the straight
end to the required dimension using the guide collar
provided.
Step 13
Lay the flue gasket onto the flue spigot and then fit
the extension pipe to the spigot using the grub
screws provided and seal using fire cement.
Step 14
Fit the spigot, 15oAdaptor and extension pipe so
that it completes the flue installation between the
stove adaptor (closure plate).
Fig.8
9
Fig.9
Tab
FRONT REMOVAL & FITTING
If necessary the front casting can be removed to
improve access at the side of the product when
making the connections. First remove the screws
fixing the door to the hinges while supporting the
door and ensuring the surface does not get dam-
aged (extra care is needed on enamel finish).
Then remove the 4 front fixing screws (see Fig.10)
which will allow the front casting and the surround-
ing shroud to be removed from the boiler by sliding
it to the left to clear the secondary air control rod and
then pulling it forward, in some circumstances it may
be necessary to unscrew the secondary air control
rod before removing the front.
Make the required connections and replace the front
in reverse order making sure that the front seals fully
to the boiler.
Step 17
Plumb the boiler - See Plumbing Section. Check all
connections for leakage before insulating the boiler
and infilling the system.
Step 18
Fill the void around boiler with fire retardant insulat-
ing wool.
Front Fixing
Screws
Front Fixing
Screws
Fig 10