Wonderfire 9500261 User manual

Senator/Liberty
INSETLIVE
FUEL-EFFECTAPPLIANCES
MODELS
NATURAL
GAS
9500260 PROPANE 9500261
Manufacturedby
Wonderfire.
Copyright
C
Wonderfire
1997.
INSTALLATION
INSTRU
CTIONS
(Please
leave
with
the
User)
Theseinstructionshave
been
writlen
toensurethe
proper
installation
ofthis
fire.
Please
read
lhemcarefullybetoreattemptingtoinstalllhefire.
9860269lssue1

DearInstaller,
AsCORGI reglstered
Installerc
ounselves,
weknowhowmuchastralghtfonvard
installation
meansto you, so we'ye trled hard to makethese Instructlons
simpleto follow andeasyto understand, whllstat the sametlme remalning
sufflclentlycomprehenslve
to helpensure
youGan
getthe lob done.
lfyouencountoranyproblems
thatthese Instructlons
don't helpyouto correct,
thenpfease calluson0117
gU 12, ,andask
tortheTechnlcal
Servle Manager.
Andlf youhave
anysuggestlons
howweoanmake
yourlob easlerInthefuture
please
letmeknow.
Technlcal
Dlrector
CONTENTS
IMPORTANTNOTES
RELATEDDOCUMENTS
TECHNICAL
SPECIFICATIONS
CONTENTS
OF
PACKAGING
PREPARATION
OF
FIREPLACE
PREPARATION
OF
APPLIANCE
GASSU
PPLY
CONT.I€CTION
ASSEMBLY
OF
FUEL.BED
INSTALLING
THE
GI-ASS
PANEL
OPERATIONOFTHE
FIRE
SPILLAGE
TEST
INSTALLING
THE
FACIA
CONSUMER
BRIEFING
SERVICING
INSTRUCTIONS
REMOVAL
OFCOMPONENTS
SPARE
PARTS
INDEX
Page
1
Page1
Page2
Page4
Page
5
Page
6
PageS
Page
9
Page11
Page12
Page14
Page15
Page16
Page16
Page18
Page19
Page20

IMPORTANT
NOTES
The
GasSafety
(lnstallation
&Use)
(Amendment)
Regulations
1990require
that
no
person
shallcarry
outany
work
inrelation
toa
gas
fitting
unlessheis
competent
todoso.CORGI isthebodyapproved
bytheHealth
&Salety
Executive
tomaintain
aregister of
competent
Gas
Installers.
In
addition,installation
must
becarried
outinaccordance with
the
Buitding
Regulations
issued
by
the
Department
oftheEnvironment
andtheBuilding
StandardsRegulations
issued
bytheScottishDevelopment
Department,
and
with
these
instructions.
lf
the
appliance
is
tobe
installed
usingamasonry
chimney
previously
used
for
solidfuel
the
chimney
must
beswept
prior
to
installation.
The
minimumheight
ofthechimney
or
flue
must
be3m
(1Oft)
from
the
hearth
tothe
point
oftermination
ofthe
flue.
The
chimneyor
flue
musthave
anydamper
or
restrictorremoved,
or
perma-
nently
securedin
the
fully
open
position.
Itis
recommended
thata
fireguard
complyingwith
8S6539
or
856778
be
fitted
for
the
protection
of
young
children,theelderly,
orthe
infirm.
fn
accordancewith
8S5871Parl2,vsntilation
isnotnormallyrequiredforthis
appliance.However,
anyr.equirement
relating
tootherapplianceswhichmay
be
in
thesame
room
must
be
takeninto
consideration.
This
appliance
isfor
useonthe
gas
supplied.
Note
thatcertain
softwallcoverings
such
as
vinylmaterials
may
stainwhen
heated.
Must
be
installed
in
accordancewith
therules
in
force.
RELATED
DOCUMENTS
BS
5440Part1,1990
BS
5440
Parl2,1989
BS715,
19g6
BS
6461
Part2,1984
BS
5871
Part2,1990
BS1251,1987
BS
6461
Part1,1984
PogeI

Tecnucal
SpecrncRnorus
Height Width Depth
Dimensions 670mm 635mm 320mm
OpeningMin 560mm 406mm
requlreo Max 575mm 460mm
Natural
Gas Propane
kW/hr BThU/hr kWhr BThU/h
Heatfnput Max 6.8 23,200 6.2 21,150
Min 3.2 10.900 3.6 12.250
Supply
Pressure (G20) 20mbar (G31)
37mbar
Setting
Pressure
(cold)
Main
burner
Maximum 17.5 mbar
(+/-1
mbar) 35.5
mbar
(+/-1
mbar)
Injectors Main
burner Cat
82-440 Cat 92-190
Clearances
To
combustibleside
panels 100mm
(4")
To
combustible
shelves 200mm
(8")
NOTE- Shelvesover 150mm
(6")
deep
willrequire
anadditional
25mm
(1")
in
clearance,
for
everyadditional
25mm
(1")
depthover
150mm.
Location
This
appliance
isnot
suitable
forinstallation
inaroom orinternal
spacecontaining
abathorshower,orin
aprivategarage.
This
applianceis
suitable
for
the
following:-
1 Minimumflueheight
of3m
(1Oft)
2 Amasonry
chimney
with
aminimum diameterof 175mm
(7")
freefrom
anyobstruction,andwith
any
damperor
restrictor
plate
in
thechimney
removed
orsecured.Amasonry
chimney
having
acorrectlyinstailed
flexiblefluelinertoBSTI5andwithaminimumdiameterof125mm(5")isalsoacceptable.
Checkthattherelevant
flatsurfacearea
is
available-seefiguresbelow.
Notethattheremaybeaneedtolocallyremovethefireplace
materials
toensuretheoutercasecaneasilvbe
installed.
700
MrN
FLAT
SURFACE
fI
I
I
700
MtN
T
SURFACE
I
I
L
xs3$'^
1
560MrN
575MAX
Fig1A.With
chairbrick
removed
Page
2
Fig1B.
With
chairbrick
in
place

3 Firebrick
(chairbrick)
removalwill
usually
be
required
unlessthedimensionsal
requirements
inFigure
1
can
bemet.
4 Asheet metalflue
system
conforming
with
854543
or
BS715,
theflue
diameter
being
aminimum
of
5"
(see
Figure
2below) with
aminimum
internal
depth
of250mm.
Incombustible
mineralwool
insulation
of
notless
than50mmthickness
must
beapplied
tothetop
surface
ofthe
system
lirebox,
as
shownin
Figure
2below.
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Figure
2
-Selkirk
recessed
factory-made
flue
system
(Part
No
04905)&5"fluearrangement
Hearth
requlrements
The
appliancemust
be
mounted
on
anon-combustible
hearthin
accordance
withFigure
3below,
being
a
minimum
thickness
of
12.5mm
(112").
The
uppersurface
ofthe
hearth
must
be
50mm
(2")
abovefloorlevel,
or
alternatively,
be
provided
with
an
upstanding
edge
ofSOmm
in
height.
300
M
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Figure
3-Hearth
dimensions
Poge3

On
no
accountmust
theappliancestand
on
combustiblematerials
orcarpets,orbe
fitted
toacombustible
wall.
Any
underfloor
airsupply
in
thefire
opening
must
besealed
with
anon-combustible
materialto
prevent
draughts.
Fire
surround
Thisappliancemaybeinstalledwith
asurroundwitha
minimum
approvedtemperature
ratingof150"C
if
fitted
in
accordancewith
these
instructions.
Thefire
sunoundmust
besealedtothe
wall
andasuitablefireplace
openingshouldbeconstructed
which
will
provide
asealed
joint
from
theopeningtothe
flueway
with
alllointsbeingsmoothandfullysealed.
See
previous
Figuresfor
dimensions.
The
surface
areaolthe
lireplacewhich
isin
contact
with
thesealing
flange
oftheappliance
must
beclean,
smoothand
flat,
in
orderto
provide
a
proper
seal
between
the
fireplace
andtheappliance.
llnecessary,the
laces
shouldbe
made
good
toensurethesealing
process.
Thefireplacefloor
(internal
hearlh)
shouldbe
reasonablyflat,
and
made
of
non-combustiblematerials.
CONTENTS
OFTHEPACKAGES
Borlof2
1no. Cast-iron
firefront
(or
outer-case),
fully
assembled,
with
gas
controlaccessdoor.
Box2of2
1no. InsetLiveFuel-Effect
heat
engine
comprisingfullyassembled
firebox
heat
exchanger,
glasspanel,
flame
sensingdevice,
ignition
system,and
ceramicburnersystem.
1no Bag
containing
14individualshaped
dresscoals
2no. Porcelain
mouldedfronl
coal-pieces
with
pilot-viewing
cut-out
1
no. Matrix
4no. Fibrewallplugs
4no. Fixing
screws
4no. Eyebolts
2no. Fixing
cables
2no. Adjusters
1no. Users
lnstructions
Remove
the
contentscarefully.Note
the
weight
ofeach
part
oftheappliancestatedonthe
outside
ofeachbox.Whenhandling
takecare
not
todamageany
ceramic
parts,
the
enameled
orother
any
othercast-ironcomponents,
the
glasspanel,
orthe
pg;9€lain
front
coals.
Page
4

PREPARATION
OF
THEFIREPI.ACE
Ensure
thatthe
fireplaceconformsto
the
previously
stateddimensional
requirements,
orcarry out
any
necessary
remedialwork.
Decideuponthepreferredmethodofretentionof
theappliance
(screworcable)and
ifnecessaryconsultwith
the
consumerbeforecommencing
work.
Screwretention
Four
screwsand
fibrewall
plugs
aresupplied
for
this
retentionmethod,to
be
located
directlythroughthe
appliance
sealing
flange
and
intothe
vertical
plane
ofthe
fireplace.
(See
Figure
4below)
Figure4-ScreworCable
retention
Ensure
all
the
fireplace
componentsaresufficiently
soundtotakethe
wall
plugs.
Drilland
plug
as
required,
carefullyfitting
onlythe
wall
plugs
atthisstage.
lf
this
methodcannotbeundertaken
without
damage
tothe
fireplacematerials,
thentheuseof
retainingcables
(betow)
shouldbe
chosen.
Cableretention
Cables
andeyeboltsare
suppliedas
an
alternative
method
of
relention.Ensurethatthe
internalfireplace
components
aresutficiently
soundtotaketheeyebottsand
wall
plugs.
Theseshouldbe
fitted
inaccordance
withFigure
5below,
usingthe
watlplugs
anda
No.10
drill.Use
onlythe
librewall
plugs
supplied
(or
similar),
onno
accountshould
plastic
wallplugs
beused.
FIBRE
RAWLPLUG
SCREWED
EYELET
CABLE
NIPPLED
CABLEEND
Figure
5
-Cable
retentionmethod&eyeboltdetail
Poge
5

Gas
supply
pipe
The
gas
supply
can
be
eilher
byconcealed
entrance,
orifpreferred
by
anexposedmethod
across
the
hearth.
The
applianceinlet
fitting
is
suitabtefor
Bmm
pipe.
lfaconcealed
method
of
supplyis
chosen,
then
the
gaspipe
must
be
instalted
atthis
stage,leaving
an
adequate
length
of
pipe
for
later
connection
to
the
fire.bn
no
account
shouldmore
than1.5ri
of
Amm
iife
be
used,
othenrise
anunacceptable
pressure-drop
may
occur.
Anisolating
elbow
orsimilar
device
should
be
fitted
close
to
thefireplace.
Only
rigid
orsemi-rigid
pipe
should
beused.
The
conce.aled
pipe
connection
can
bebrought
in
through
one
ofthe
grommeted
holes
totheleft,
right
or
rear
ofthe
appliance
sheet.metal
housing.
Leave
the
grommet
in
positiJn
to
protect
the
gas
pipelouier
shroud
interface,
making
ahole
in
the
grommet
suitablefor
the
gas
iipe
to
pasi
through.
GASPIPE
ENTRY
POINTS
(3off)
Figure
6
-Conceated
firlng
.gas
entry
opilons
Ensure
allcombustible
materials
are
removed
from
thefireplace
area.
PREPARATION
OF
THE
APPLIANCE
Openthe
packaging,
remove
theinternal
packaging
and
place
toone
sideforlater
use.Remove
the
sleeve
from
thepackaging,
giving
access
to theappliance.
Remove
theglass
panel
by rotating
theupper
retaining
clips
(Figure
16Page
11)
to
clear
the
panel.
Lift
the
panel
upwaids
andouttrom
thetirebox
assembly.
Carefully
place
the
panelwhere
it
willremain
secure.
The.burnerassembly
isretained
bytwo
screws
set
intotheverlicals
of
thefirebox
assembly.
Carefullyremove
theburner
assembly
byslidingfonrard
from
thefirebox.
Place
in
asafe
position,
being
carefulnot
to
damage
anyceramic
parts.
Check
the
flue
restrictor
plate
onthe
upper-rear
sheetmetal
apptiancehousing,
and
adjust
tothe
appropriate
position
(Figures
7
&8overleaf),
A
orB.
'A'for175mm
diameter
(and
larger)
llues
Page
6
'B'
for125mm-174mm
diameterflues

@
BEND
THIS
TAG
BACK
FOR
FLUES
LESS
THAN
175
DlA.
(as
shown)
Flgures7&8
- Restrlclor
positlon
"A"for175mmfluss,Restrlctor
posltlon
"8" for125mmflues
Note
thatthecorrect
positioning
ofthis
restrictorisimportant
(Figures
7&8above). Failuretoposition the
restrictorcorrec'tlycould
cause
spillage,orreducetheefficiencyofthe
appliance.Checkthatthe
sealing
rope
is
correctly
fitted
ontothe
roperetaining
tags
atthe
rear
of
theappliance
sealing
flange.
Take
thecardboard
internalpackagingmentioned
earlier,and
place
itflat
onthe
hearthto
protect
against
damage.
Placethe
applianceonthecardboard
wheremarked,
andoffer
it
uptothe
fireplaceopening
-
sliding
theapplianceandcardboardtogether.Carefully
lifting
theappliarrce
slightly,
remove
thecardboard.
Ensure
thatthesealing
ropewilleffectively
sealagainst
the
verticalplane
ofthe
lireplace.
lf
aconcealed
gaspipe
lixingis
to
be
used,offerthe
gaspipe
throughthe
appropriate
grommet.
Screw
retalnlng
method
Carefully
manoeuvre
theappliance
into
the
fireplace
opening,
removeallofthecardboard
pad,
and
fix
throughthe
appliance
sealing
flange
tothe
vertical
plane
ofthe
fireplace,
usingthescrews
supplied.
Take
caretoensuretheappliance
issecured
evenly
in
orderto
provde
aneffective
seal.
Do
not
overtighten,
as
thismaycausedamagetocertain
fireplace
materials,
suchas
marble
orconglomerates.
Cable
retentlonmethod
Assemble
the
cablethroughthe
eyeletsand
litadjusters in
accordance
with
Figure
9overleaf.
With
the
adjustersscrewed-infully,
carefully
manoeuvre
theappliance
into
the
fireplace
opening.
Take
upanyslack
onthecables,
andtightencable
nipples
into
position.
Tighten
theappliance
into
the
fireplace
openingby
turning
the
adjuster
nutstocompressthe
sealing
rope
sufficientlyto
provide
an
effectiveseal.
Donot
overtighten.
lfthesealing
rope
does
notfully
compress,thenthe
adjustersand
nipples
mayrequiretobeslackened,
and
thecable
pulled
up
tighterbefore
retightening
theadjuster.
Donot
cut
offanyexcess
cable,
instead
coilup
thecable
against
the
flange,
as
itmaybe requiredfor
servicing
purposes.
PogeT

ADJUSTER
SCREWED
NIPPLE
ADJUSTER
NUT
CABLE Figure
9- Cableadjustment
GASSUPPLYCONNECTION
Note:
Beforemaking
the
f
inal
connection
tothe
gas
inletfitting,
purge
thesupplyofallairanddebris.
Concealed
gas
connection
Replace
theburnerassembly
into
position
in
the
firebox,withoutrefittingthe
retaining
screwsatthis
stage.Cutand
shape
the
gas
supply
pipe
tosuit
thechosen
directionof
entryandthe
gas
inlet
fitting
position.
Note
thattheinletfitting
elbowcanbe
loosened
andswivelledtoallow
forleft-
or
right-hand
gas
connection.
See
Figure10,
below.
Refit
andtightentheburnerassembly
retaining
screws.
Exposed
gas
connection
Replace
theburnerassemblyinto
position
in
the
firebox,
wilhoutrefitting
the
retaining
screwsatthis
stage.
Using8mmdiameter
rigid
orsemi-rigid
pipe,
runthe
pipe
from
the
gas
inletfitting
toasupply
restrictor
elboworsimilar
adjacenttothe
fireplace.
Figure11
(overleaf)
shows
alternativesupply
routes
forleft
or
right-
hand
connection.
Figure10
-Left
orRight-hand connection
Page
8

ALTERNATIVE
LEFT
HAND
SUPPLY 8mm
SUPPLY
PIPE
FITTIGHT
ALONG
BOTTOM
EDGE
OFFI.ANGE
Figure11
- LH
or RH connectionof exposed
gas
supply
Note
thatthe
pipe
must
exittheappliancethroughthe
slot
in
theoutercasecolumn,
orbeneath
the
fender,
andshouldberouted
accordingly.
Refit
andtighten
theburnerassembly
retaining
screws.
Note:
ensure
thecontrol
knobis
centrally
locatedwithin
thedatabadge
plate.
Gassoundness
check
Turn
onthe
gas
supplyand
conductagas soundnesstest.
ASSEMBLY
OF
THEFUEL-BED
HANDLE
ALL
CERAMICFUEL-BEDPARTSTENDERLY
Senator
usesa fuel-bedassemblywhichhasbeen
proven
in more
than 100,000 applications
throughout
the
world.Allthe
ceramic
parts
are
safeto
handle,
and
aredesigned
tobe
easily
replaced
bythe
installer,
service
engineer,
ortheconsumer.
Thisfire
uses
apair of
hard
ceramic
(porcelain)
mouldedfront
coals
(Figure
12
below)
which
should
behandled
with
care.
Viewing
from
the
front
there
is
acut-outfor
pilot
viewing.
Each
piece
should
be
placed
intoits
correct
position
in
lurn,
with
the'coal'shapes
facing
lhe
installer,
locating
the
two
retaining
lugsinto
therectangular
slots
in
thefront
edgeoftheburnerasshown
inFigure
12
below.
Gently
push
downwards
untilthecoal
pieces
are
located
securely,andthe
slottedareaontheir
lower
surlace
touches
theburner
base.
Figure
12 -Placing
the
front
coaland
mouldedmatrix.
The
matrixmust
be
locatedfully
againsttherear
of
thefirebox
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9

I
I
t
Place
the
moulded
coal
matrix
(Figure
12
previouspage)
on
theuppersurface
of
theburnerand locate
itfully
againstthe
rear
ofthe
fireboxin
acentral
location.
Takefive
(5)
dress
coals
from
the
bagof
fourteen
(14),placing
themso
that
themost
realistic
surfaces
may
be
seen
from
the
front
ofthe
fire,
andensuring
they
bridge
thespacebetween
the
moulded
front
coal
pieces
and
the
front
edgeofthe
matrix,
as
shown
inFigures
13
&14 below
Figure
13
- Placing
the
firstfive
dresscoats
A random,realistic,
effect
may
bemade asitisnotnecessary
thattheshapesareallpositioned
inthe
same
manner,
although
the
coals
shouldbe
generally
equally
spaced
forthe
best
flame
effect.
Take
care
not
toallowany
part
ofthe
five
dresscoalstolocate between
the
rear
ofthe
front
coal
pieces
and
the
vertical
serratedsurfaceat
the
front
of
the
burner.Thecorrect
position
is
shown
inFigure14
below.
FRONT
COALS
VIEWTO
SHOW
BRIDGING
Figure14
- Bridging
the
front
coalsandmatrixwith
6dresscoals
Place
afurther
row
of
five
(5)
coalsonthe
matrixin
arandomfashion abovethe
first
sixcoals
previously
placed,
asshown
inFigure15
overleaf.
Then
place
the
remainingfour
(4)
coals
in
arow on
thesurfaceofthe
matrix
abovethesecond
row
ofcoals,
leaving
a spacebetween thesetwo
rows
toallowthebest
flame
effect.
Ensure
agenerally evenspacingbetweenall
the
coals
forthe
besteffect.
i;; f. it --
\tl ,-
z.
ril -/
1r',
f. V. * iY .:'1 U
i" \i ,l |}
i i' t',1-'^
* )lr
.l: illit
l'
*:J ,'^
t I
fA tA,^ '
?u,.,n!d_a(
Page
10

Figure
15
- Placing
the
remaining
dresscoals
intworows
offive
(5)
and
four
(4)
INSTALLING
THEGLASSPANEL
Take
care
whenhandling
the
glasspanel
Take
theglass
frame
assemblyandoffer
upcentrally
to thefabricated steel
firebox.
Insert
thelower
cornersofthe
frame
assembly
into
theUchannel
locations
on
the
firebox.Line
up
theupper
location
points
and
withthethumb
screws
provided
tightentheuppersectionof
the
glass
assembly
onto
the
firebox.
To
ensure
a
tightseal
is
achieved,theuseofa
flatheaded
screwdriver
will
be
required
in
order
tobed
downanew
seal.
Figure16
-The
glass
retainingclips
Poge1I

OPERATIONOFTHEFIRE
Before
installing
thecast-ironfirefront
(outer
case)
please
observethe
lmportantNotes
on
Page
1
of
theUsersInstructions,
beforeattempting
to
operate
thisappliance.
Read
these
instructions
thoroughly
beforeoperating
the
fireforthefirst
time.Ensure
the
gas
supply
is
purged
ofairbeforeattempting
to
light
the
firefor
the
first
time.
The
Gas
Control
This
fireiscontrolledby
afour-position
gas
controlmounted
onthe
lowerright-hand
sideofthe
appliance,
behindtheflush-fitting
access
door.
In
additiontothe
OFF
position,
there
is
aPILOT LIGHT
position,
andtwo
HEAT
CONTROL
positions
(see
Figure17
below).
Figure17
- lgnition
andheat control
posltlons
lgnition
ofthe
fireis
by
piezo
whichignites
the
pilot
flame.Themain
burner
islitfrom
this
pilot.
Lighting
thePllot
Ensure
that
the
gas
supply
is
on.
Turn
the
gas
control
knob
totheOFF
posilion.
Depress
thecontrol
knob
andturnanticlockwise
untilthePILOT
position
is reached.lgnite
thepilot
flame.Keep
theknob
depressed.
Observethe
pilot
flameis
alightby
viewing
the
lower
edgeofthe
fuel-bed
onthe
left-hand
sideofthe
fire,
through
thecast
ironfretwork
abovethe
fender.
(Figure
18
below).
PILOT
VIEWING
Page12

Lighting
the
main
burner
Themain
burner
can
be
lit
bydepressingandturningthecontrol
knob
anticlockwisetothe
MAXIMUM
position
(Figure
17)
To
turnthe
fire
OFF
Depress
thecontrol
knob
and
turnclockwiseuntilthe
OFF
position
has
been
reached.
Observethat
the
pilot
isnow
extinguished
(Figure
17).
Checkthatthe
applianceoperatessatisfactorily
inallcontrol
positions.
Note
thatthe
fuel-bedmay
takeup
to
15minutes
to
provide
a
realistic
glow,
and
thatthe
flames
will
be
predominately
ofabluecolouruntilthe
firehas
completely
heated
up
to
its
usualoperatingtemperalure.
Thisis
normal.
Lighting
the
firewith
ataper
ln
theeventof
failure
ofthe
piezo
spark
generator,
the
pilot
flame
canbe
lit
byataper,spill,or
long
matchinserted
throughthe
fretwork
abovethe
fender
to
reach
the
pilot
light
(Figure
19
below).
Follow
the
lighting
instructions
aboveuntilthe
pilot
flame
can
be
established.
INSERTSPILL
OR
TAPER
THROUGH
SLOT
INFENDER
Checktheburner
pressure
Light
the
firein
accordance
with
the
lighting
procedures
outlinedabove.
The
appliance
is
pre-set
togive
thecorrect
heatinput
at20 mbarNG.;37 mbarLPG.
inlet
pressure.
The
burner
pressure
should
be
checkedat
the
pressure
test
point,
usingasuitable
gauge(Figure
20
below).
Figure
20
-PressureTestPolnt
Poge13
Figure19
-Lightingwith
ataper

With
the
applianceoperating
in
the
MAXIMUM
position
the
burner
pressure
shouldbe
in
accordance
withTechnical
Specifications,
Page2.After
checkingthe
pressure,
turnofftheapplianceand
replace
thetest
point
sealingscrew.
Relight
theappliance,turnto MAXIMUM,
and
test
around
thesealingscrew
for
gas
soundness.
SPTLLAGE
TEST
This
spillage
test
must
beconductedtoconfirmthesafeclearance
ofcombustion
products.
Light
the
fireifitisnot
alreadyoperating,
andallowto
warm
up
forfiveminutes
atthe
MAXIMUM
position.
Place
asmoke
matchinto
thespillage
sensingtube
(Figure
21
below)
so
asthe
wholehead
ofthe
matchis
atleast12mminside thetube.
MATCH
HEAD
12mm
INTOTUBE
Figure21
- Conduct
aSpillage
Test
Observe
thesmoke,
ifitis
drawn
into
thetubethentheappliance
is
clearingthecombustion
products
satisfactorily
lf
smoke
expels
from
thetube
then
allowtheapplianceto
warm
up
for
a
further
ten
(10)
minutes
and
repeat
the
test.
lf
spillageoccurs
remove
theappliance
from
the
fireplace
opening,and
adjustthe
flue
outlet
restrictormountedonthe
rearof
thefirebox
(See
Figures7and8
PageT)tothefullyopenpositionfor5"flues,
allowtowarm
upand
repeat
thetest.
lfspillagecontinuestooccur, donot
proceed.
Seek
expertadvice.
Additionally,
if
anextractor
fanisfittedin
thesame
-
or
a
communicating
-room
space,
acheckshould
becarried
out
with
doorsand
windows
closedandthe
fan
tumedon.
lf
the
appliancecontinuestospill,thecause
mustberectified
before
proceeding
withtheinstallation.
Before
undertaking
the
following
procedures,
ensurethatthe
firehas
been
previously
switched
off
,
and
has
beenallowedtocoolcompletely.
INSTALL|NGTHE
CAST-|RONFTREFRONT
(OUTER
CASE)
Please
readthese
instructionsfully
beforeattemptingtoinstallthefirefrontforthe
first
iime.
THE
CASTIRONFIREFRONTISHEAVY
The
cast-ironfirefront
(outer
case)suppliedwith
Senator
is
a high
quality
castingweighingaround28kgs
(60lbs).
lf
you
have
anydoubtof
your
abilitytoeasilylift
or
remove
this
component,
you
shouldasksomeone
toassist.
Like
the
SenatortheLibertyweighs
around28
kgs
(60lbs).
lfyou
have
anydoubt
of
your
abilityto
easily
lift
orremove
this
component,
you
should
asksomeone
toassist.Duetothe
curved
nature
of
the
casedesignLibertyrequires
careful
lifting
ontotheheat
engine,
if
you
utilise
the
convection
air
or
fender
aperturesforlifting
becarefulnotto
pass
your
fingers
throughtheapertures
due
the
possibilty
of
pinching
when
offering
uptothe
engine. Page14

Assistancewillalsohelp
avoiddamagetothe
tirefrontcomponent
itself
,
the
painted
orenameled
finish,
the
fire
surroundand
fireplacecomponents,and
will
avoid
possible
injury
to
yourself
.Youmay
wish
toutilise
thecardboard
packaging
again,toavoiddamgetothe
hearthor
firefront
component.
Note
the
the
firefronthas
two
lugs
cast
into
the
rear
ofthe
mantleshelf,andlwosteel
lugsattached
to
lhe
rear
ofeach
verticalcolumn
whichlocate
into
theslots
in
thesheet
metal.Carefully
lift
the
firefrontinto
aposition squaretothesealing
flangeoftheappliance,some
1"
(25mm)
aboveandaway
from
the
four
location
slots
formedin
thesheet
metal
ofthechassissealing
frame
(Figure
22
below).
Figure
22
- Install
the
firefrontintotheslots
provided
Holdingthe
firefront
alittleabovethetop
surfaceofthechassis
sealing
flange,
locatethe
fixinglugs
into
theslots
provided
in
thesealing
flange,
push
carefully
towards
the
fireplace,and
GENTLY
lower
the
componentontothe
hearth
ensuringthat
nodamageoccurstothe
finishofthe
f
acia,or
tothe
hearth
material
itself.
Allfourfixing
lugs
should
locateintotheslots,andthe
firefront
should
sitsquarely
onthehearth,
locating
againstthe
vertical
surface
ofthe
fireplace.
Note:lf
thegas
supply
is
acrossthe
hearth,
ensurethatthe
supply
pipe
islocatedthrough
the
purpose-
provided
slot
in
the
firefront
casting.(Figure
23below).
Theinstallation
isnow
complete,
please
briefthe
consumer.
GAS
SUPPLY
CUT-OUT
\rrrr."
Figure
23
-Ensuringanexposed
gas
supply
enters
correctly
PogelS

CONSUMER
BRIEFING
Oncethe appliance hasbeenfullyinstalled
andcommissioned,
instruct
the Useron its correct
operation.
The
cleaning
procedures
recommended
in
theUsers
Instructions
shouldbe
explained
in
detail,and
coal
placement
explained.
The
consumermust
bewarned not
tovary the
coal
layout,
andofthedangersof
addingextra
@als,orofoperating
theappliance
without
theglasspanel inplace.
Explainhow
thefirefrontmay beremoved
and
refitted,
and
suggestthattheelderlyorinfirmrequest
assistance
in
theeventthe
firelrontrequires
renpval.
Inform
the
consumerthatanyservicing
is
tobe carried
ofi byaCORGI
installer.
TheseInstructions
should
beleftwith theconsumer.
Explain
thatthe
appliance
isfittedwith
an
A.S.D.
(Atmosphere
Sensing
Device).
lfthe
appliance
closesdownafter
a period ofoperation
for
no
apparent
reason,
theconsumershouldbe
informed
to
stopusing
the
appliance,
untilthe
installation
andappliance
have
been
thoroughlychecked.
SERVICING
INSTRUCTIONS
Glass
Panel
Occasional
cleaningofthe
inside
ofthe
glasspanel
may
berequired
betweenservices.
Instruclions
for
this
procedure
arecontained
in
theUsers
Instruclions.
Regular
Servicing
Allow
the
applianceto
cool
completely
if
it
has
beenoperating.
lsolate
the
gas
supplytothe
appliance
prior
tocommencing work.
HANDLEALL
CERAMIC
FUEL.BED
COMPONENTS
TENDERLY
Senatorusesa fuel-bedassembly whichhasbeen
proven
in more
lhan 100,000 applications
throughout
the
world.Allthe
ceramic
parts
aresafe
to
handle,
andaredesignedtobe
easily
replaced
bythe
installer,
serviceman,
orconsumer.
The
fourteen
(14)
individual
dresscoals
(Figure
15 Page1'1)
shouldbe removed,
noting
their
approximate
positions
to
facilitatereplacement,
andthen
placed
ona
piece
of
newspaper.Any
depositscan
becarefully
removedfrom
thesurfaceofthecoals
usingasoftbrush
(such
asapaint brush).
The
two
parts
ofthe
porcelain
ceramic
front
coals
(Figure
12Page
9)andthe
moulded
ceramiccoal
matrix
(Figu
re
12Page
9)
should
now
be
removedfrom
the
burnersurface,
noting
their
positions
and
location
tosimplifyreplacement.
Theymay
becleaned
with
asoft
brush.
The
burnersurface,
three
flue
outlet
ports
and
firebox
surfaces
may
be
CAREFULLYcleanedbythe
use
ofa
vacuum-cleaner
USINGONLYA
SOFT
BRUSHATTACHMENT.
Remove
only
loose
particles,
and
ensurethatlheburnersurface,
burnerports,and
moulded
shapesarenot
inanywaydamaged
bythecleaning
actiort
Inspection
ofthe
burner
Disconnect
the
gas
supply
from
the
gas
inletfitting
atthe
front
oftheburnerassembly.
(Figurel
0Page
8).
Remove
the
twoburnerassembly
retaining
screws,
andslidethe
assembly
outofthe
firebox,
taking
care
nottodamage
anyceramiccomponent.
Anydepositsordebris
shouldbecarefullyremoved
with
a
SOFT
BRUSH.
The
burner
slotsshouldbe
inspected
toensuretheyareclear
ofdebris,andanyblockagescarefully
removed.
Onno
accountshould
toolsbeused
which
may
enlargeordamagetheburnerslots.
The
burner
surfaceshould
beinspected
lordamage.
Consultthemanufacturerfor advice
ifinany
doubt
ifdamageispresent.
Anysurfacecrazingoftheceramicsurfaceof theburner,
matrix,
and
fuel
componentsis
usualand
isno
cause
lor
concern.
Page16

Check
the
injectorand
venturi
for
linting
or
obstruction.
lf
there
is
a
needto
remove
the
injector,
please
see
RemovalofComponents.
Checkthe
injector
remains
aligned
correctlyto
fire
centrally
intothe
venturi.
Adjustthe
iniector
position
as
required.
Checkthesmooth
operation
of
thecontrol
tap,
the
Integrilyofthe
gas
train,and
the
piezo
ignition
lead
andconnections.
Remove
any
depositsordebris
from
around
the
pilot
light,
andcheck
thatthe
piezogenerator
is
sparking
correctlyby
operating
thecombined
tapand
piezo
control.
Ptacetheburner
assembly
toone
sidetaking
care
not
todamage
theceramic
components.
Inspect
the
flue/chimney
Remove
the
four
retaining
screws
from
the
appliance
sealing
flange
(Figure
4Page6)or
alternatively
slackenthecable
adjuster
and
remove
thecable
nipples,
iffitted
(Figure
5Page5).
Carefully
slide
theappliance
out
ofthe
fireplaceopening,
ensuring
nodamage
occurs
tothe
hearth
material.
lnspectthe
general
condition
of
the
flueand
removeany
deposils
ordebris
fromthe
fireplace
opening
or
flueways.
Repairanycracking
inthefluewaybefore
reassembling.
InspecttheconditbnoJthe
rope
sealand
also
ensurethis
is
correctly
positioned
toensure
an
effective
seal.
Ensureth€
ropeseal
isfully
intactbefore
re-
fitting.
R+installthe
appliance
in
accordance
with
the
installations
instrudirrs
contained
herein.Care
must
betakentoensure
thecorect
appliance
sealing
and
fuel-bed
layort.
Commission
the
firein
accordarrce
with
the
lnstallation
Instructions.
Conduct
agas sotndness
test,
and
allue spillagetest
to
verifythesafe
operation
ofthe
appliance
as
prwiously
described
(Page
14).
Leave
these
instruction
with
theUser.
REMOVAL
OF
COMPONENTS
Removal
ofthe
A.S.D.
(AtmosphereSensing
Device)
Remove
the
burner
assembly
in
accordarrce
withthe
instructions
on
Page
16.
Taking
care
not
to
damagethe
ceramic
components,
inverttheburner
assenrbV
anddisconnect
the
thermocouple
nutatthe
gas
control.
Disconnectthe
pilot
supply
pipe
at
the
A.S.D.end,
and
carefully
withdraw
the
Assembly.
Disconnecttheelectrode
leadat the
A.S.D.end.
Remove
the
twoscrews
holdingthe
pilot
burner
assembly
totheburner
tray.
The
pilot
assembly
maynowbe
removed.
Re'assemble
in
reverseorder'
Poge
17

Removal
of
the
gas
control
Remove
theburnerassembly
in
accordarrce
with
the
instructions
on
Page
16.
Taking
care
nol
to
damagetheceramiccomponents,
inved
thehrmerassemblyanddisconnec'tthe
thennocouple
nutfrom
the
gas
control.
Disconnectthe
pilot
supply
pipe
attho
gas
controlend.Disconnect
the
main
htmersupply
pipe
atthe
gas
controlend.
Disconnect
the
inlet
pip€
at
the
gas
controlend.
Remove the gas control retaining locknut from the control mounting brackets and withdraw
the control. Re-assemblein reverseorder.
Removal
olthemalnburnerInlector
Remove
thebumerassembly
in
accordance
with
the
instrucltions
onPage16.
Taking
care
notto
damage
theceramic
components,
inveil
thebumerassemblyanddisconnect
the
main
burnersupplypipefromtheinjectorend,takingcaretosupportthetumingaaionbyretainingtheinjeclor
position
usiningasuitablespanneronthesquareend.Unscrewtheini€ctor.
Re-assembleinreverse
order,
ensuring
theconectalignmentofthe
injectorfiring
downthecentre-
line
olthe
venturi.
Assembly
oftheFlrefronUOuter
Case
ln
theeventof
damagetotheOuterCase,the
individualcastings
may
be
replaced
asbllows.
Remove
thedamagedOrter
Gaseas
describedonPages14115.
Dis-assemblgthe
case
into
ths
five
castcomponents
by
removing
the
nutshoHing
the
assembly.
Remove
thedamagedcomponent,
and
replace
the
new
one
in
position.
Carefully
replace
andtightenthe
nulswithout
damaging
lhe
painted/enameled
finish
byuseofundue
pressure.
Re-installthe
OuterCase
following
the
instructions
on
Page14115.
NOTE
Libertyis
aone
piece
castingwith
only
the
controldoor
accesscastingbeing
replaceable
asan
individual
item.
Page18