Wonderfire 963 Instructions for use

5140182/02
© GDC Group Ltd. 2012
Model 963
Inset live fuel effect gas fire
Fitted with the Bauhaus fascia.
(G.C. Number 32-032-92)
INSTALLE AND OWNE GUIDE
Please keep me in a safe place for future use.
We trust that this guide gives sufficient details to enable this appliance to be
installed, operated and maintained satisfactorily. owever, if further information is
required, our Wonderfire Premier Technical Helpline will be pleased to help.
Telephone [phone] (National call rates apply in the United Kingdom).
In the Republic of Ireland Telephone [phone] .

© GDC Group Ltd. 2012.
All rights reserved. No part of this publication may be reproduced in any material form
(including photocopying), stored in any medium by electronic means (including in any
retrieval system or database) or transmitted, in any form or by any means, whether
electronic, mechanical, recording or otherwise, without the prior written permission of
the copyright owner.
Applications for the copyright owner's permission to reproduce any part of this
publication should be made, giving details of the proposed use, to the following
address: The Marketing Communications Manager, GDC Group Ltd, Millbrook ouse,
Grange Drive, edge End, Southampton, SO30 2DF.
Warning: Any person who does any unauthorised act in relation to a copyright work
may be liable to criminal prosecution and civil claims for damages.
www.wonderfire.co.uk
Because our policy is one of constant development and improvement, details may vary
slightly from those given in this publication
© GDC Group Ltd. 2012 Page 2
THIS APPLIA CE IS FOR USE WITH ATURAL GAS (G20).
U DER O CIRCUMSTA CES IS THIS FIRE TO BE CO VERTED TO LPG.
A LPG KIT DOES OT EXIST FOR THIS GAS FIRE.
THIS APPLIA CE IS SUITABLE O LY FOR I STALLATIO I THE U ITED
KI GDOM (GB) A D THE REPUBLIC OF IRELA D (IE).

Safety First.
Wonderfire Premier fires are CE Approved and designed to meet the appropriate
British Standards and Safety Marks.
Quality and Excellence.
All Wonderfire Premier fires are manufactured to the highest standards of quality and
excellence and are manufactured under a BS EN ISO 9001 quality system accepted
by the British Standards Institute.
The Highest Standards
Wonderfire is a member of SBGI and IC ( eating and ot water Industry Council)
that work to ensure high standards of safety, quality and performance.
Careful Installation
This gas fire must be installed by a competent GAS SAFE REGISTER operative in
accordance with our installer guide and should not be fitted directly on to a carpet or
floor of combustible material.
© GDC Group Ltd. 2012 Page 3

© GDC Group Ltd. 2012 Page 4
INSTALLER GUIDE
FOR OWNER GUIDE SEE PAGES 45 TO 63
INSTALLE GUIDE

CONTENTS
Section Heading Page
I STALLER GUIDE 4 - 44
OW ER GUIDE 45 - 63
1. IMAGE 7
2. SAFETY A D U PACKI G 8
3. APPLIA CE DATA, EFFICIE CY A D Ox 9
3.1 General information. 9
3.2 Efficiency. 10
3.3 NOx 10
4. GE ERAL I STALLATIO REQUIREME TS 11
4.1 Regulations, Standards and Law. 11
4.2 Ventilation requirements. 12
4.3 The Atmosphere sensing device (ASD). 12
4.4 Fireguard requirements. 12
4.5 Room considerations. 12
4.6 Chimney preparation. 12
4.7 Fireplace preparation. 13
4.8 The hearth and back panel. 13
4.9 Fireplace clearances. 14
4.10 Installation options. 16
4.11 Flues. 19
5. PACK CO TE TS 20
6. FIREPLACE CHECK 22
6.1 Soundness for appliance attachment. 22
6.2 Fireplace flue pull. 22
7. IG ITIO CHECK 23
8. GAS SUPPLY CO ECTIO 24
9. PREPARI G APPLIA CE FOR I STALLATIO 24
9.1 Appliance preparation. 24
9.2 Fitting the foam seal. 25
9.3 The flue restrictor. 26
© GDC Group Ltd. 2012 Page 5
Continued on next page
INSTALLE GUIDE

CONTENTS (Continued)
Section Heading Page
10. CO VECTIO BOX I STALLATIO 27
10.1 Method 1- Front fixing to fireplace surround. 27
10.2 Method 2 - Cable retention. 27
10.3 Floor sealing. 29
10.4 Sealing convection box holes. 29
11. BUR ER A D SUPPLY PIPE I STALLATIO 30
11.1 Burner and supply pipe installation. 30
11.2 Preliminary burner checks. 30
11.3 Inlet pressure check. 31
12. FITTI G THE CERAMIC FUEL EFFECT 31
13. FITTI G THE WI DOW 31
14. SPILLAGE A D FLAME SUPERVISIO CHECKS 32
14.1 Check for spillage. 32
14.2 Flame supervision and spillage monitoring system. 33
15. FITTI G THE HEAT BAFFLE 34
16. FITTI G THE FASCIA 34
17. FIREFRO T CASTI G I STALLATIO 35
18. FULL OPERATI G CHECKS 35
18.1 Recheck the control settings. 35
18.2 Lighting the burner. 36
18.3 Operating the burner. 36
19. FI AL REVIEW 37
20. SERVICI G & PARTS REPLACEME T 38
20.1 Checking the aeration setting of the burner. 39
20.2 To remove the ignition microswitch. 39
20.3 To remove the gas shut-off microswitch. 39
20.4 To remove the fascia. 40
20.5 To remove the window. 40
20.6 To remove the burner unit. 40
20.7 To replace the control slide knob. 41
20.8 To remove the electronic ignition generator. 41
20.9 To remove the thermocouple interrupter block. 41
20.10 To remove the pilot unit. 42
20.11 To remove the shut-off tap. 42
20.12 To remove the gas flow rate controller. 43
20.13 To remove the burner. 43
20.14 To remove the main burner injector. 44
20.15 To remove the appliance from the fireplace. 44
© GDC Group Ltd. 2012 Page 6
INSTALLE GUIDE

1. IMAGE
© GDC Group Ltd. 2012 Page 7
INSTALLE GUIDE

2. SAFETY AND UNPACKING
Installer
Before continuing any further with the installation of this appliance please read the
following guide to manual handling.
-The approximate lifting weight (kg) of this appliance is as below:
eat Engine Firefront and ash pan Fascia Combined Weight
11.28 4.51 7.53 23.32
-One person should be sufficient to lift the fire. If for any reason this weight is
considered too heavy then obtain assistance.
-When lifting always keep your back straight. Bend your legs and not your back.
-Avoid twisting at the waist. It is better to reposition your feet.
-Avoid upper body/top heavy bending. Do not lean forward or sideways whilst
handling the fire.
-Always grip with the palm of the hand. Do not use the tips of fingers for support.
-Always keep the fire as close to the body as possible. This will minimise the
cantilever action.
-Use gloves to provide additional grip.
-Always use assistance if required.
-This product uses fuel effect pieces containing Refractory Ceramic Fibres
(RCF), which are man-made vitreous silicate fibres. Excessive exposure to
these materials may cause irritation to eyes, skin and respiratory tract.
Consequently, it is important to take care when handling these articles to
ensure that the release of dust is kept to a minimum. To ensure that the release
of fibres from these RCF articles is kept to a minimum, during installation and
servicing we recommend that you use a HEPA filtered vacuum to remove any
dust and soot accumulated in and around the fire before and after working on
the fire. When replacing these articles we recommend that the replaced items
are not broken up, but are sealed within a heavy duty polythene bag, clearly
labelled as RCF waste. RCF waste is classed as a stable, non-reactive
hazardous waste and may be disposed at a landfill licensed to accept such
waste. Protective clothing is not required when handling these articles, but we
recommend you follow the normal hygiene rules of not smoking, eating or
drinking in the work area and always wash your hands before eating or
drinking.
-This appliance does not contain any component manufactured from
asbestos or asbestos related products.
© GDC Group Ltd. 2012 Page 8
INSTALLE GUIDE

3. APPLIANCE DATA, EFFICIENCY AND NO
x
3.1 General information.
Under no circumstances is this fire to be converted to LPG. An LPG conversion kit
does not exist for this gas fire.
The appliance information label is located on a ‘swing out’ plate at the base of the
fire. On fires that are already installed this can be seen by removing the bottom front
cover of the fascia.
© GDC Group Ltd. 2012 Page 9
Gas atural (G20)
Inlet Pressure 20mbar
Input - Max. (Gross) 3.9kW (13,307 Btu/h)
Input - Min. (Gross) 2.3kW (7,848 Btu/h)
Input - Max. (Net) 3.51kW (11,976 Btu/h)
Input - Min. (Net) 2.07kW (7,062 Btu/h)
Inlet Test Pressure (Cold) 20.0 ± 1.0mbar (8.0 ± 0.4in w.g.)
Gas Connection 8mm pipe
Burner Injector Cat 82 - 280
Pilot & Atmosphere Sensing Device Copreci Ref. O.D.S 21100/234
Ignition Electronic (Alkaline 9V PP3 Battery)
Aeration See section 20.1
Figure 1.
INSTALLE GUIDE

3.2 Efficiency.
The efficiency of this appliance has been measured as specified in BS 7977 - 1 and
the result is as below:
Model Efficiency % (Gross) Efficiency % ( et)
963 80 89
The gross calorific value of the fuel has been used for this efficiency calculation. The
test data from which it has been calculated has been certified by BSI (0086). The
efficiency value may be used in the UK Government's Standard Assessment
Procedure (SAP) for energy rating of dwellings.
The conversion of net efficiency to gross was achieved by multiplying the net
efficiency by the following conversion factor from Table E3 of SAP 2005, rounding
down to the nearest whole number.
3.3 Ox
The 'Weighted' result for this appliance equates to NOx Class II.
© GDC Group Ltd. 2012 Page 10
Gas Conversion factor from net to gross efficiency
Natural Gas 0.901
INSTALLE GUIDE

4. GENE AL INSTALLATION EQUI EMENTS
4.1 Regulations, Standards and Law.
The installation must be in accordance with these instructions.
For the user’s protection, in the United Kingdom it is the law that all gas appliances
are installed by competent persons in accordance with the current edition of the Gas
Safety (Installation and Use) Regulations. Failure to install the appliance correctly
could lead to prosecution. GAS SAFE REGISTER require their members to work to
recognised standards.
In the United Kingdom the installation must also be in accordance with:
All the relevant parts of local regulations.
All relevant codes of practice.
The relevant parts of the current editions of the following British Standards:-
BS EN 1856 Part 1 - Chimneys - Requirements for metal chimneys.
BS 715 - Specification for metal flue boxes for gas-fired appliances not
exceeding 20kW.
BS EN 1858 - Chimneys - Components - Concrete flue blocks.
BS EN 1806 - Chimneys - Clay / ceramic flue blocks.
BS 5440 Part 1 - Installation of flues.
BS 5440 Part 2 - Installation and maintenance of flues and ventilation for gas
appliances of rated input not exceeding 70 kW net (1st, 2nd
and 3rd family gases).
BS 6461 Part 1 - Masonry chimney & flues - Installation
BS 1251 - Fireplace components
BS 5871 Part 2 - Installation - Inset LFE gas fires
BS 6891 - Gas pipework installation
-In England and Wales, the current edition of the Building Regulations issued by the
Department of the Environment and the Welsh Office.
-In Scotland, the current edition of the Building Standards (Scotland) Regulations
issued by the Scottish Executive.
-In Northern Ireland, the current edition of the Building regulations (Northern
Ireland) issued by the Department of the Environment for Northern Ireland.
-In the republic of Ireland the installation must be carried out by a competent person
and also conform to the relevant parts of:
a) The current edition of IS 813 “Domestic Gas Installations”
b) All relevant national and local rules in force.
Where no specific instructions are given, reference should be made to the relevant
British Standard Code of Practice.
© GDC Group Ltd. 2012 Page 11
INSTALLE GUIDE

4.2 Ventilation requirements.
Normal adventitious ventilation is usually sufficient to satisfy the ventilation
requirements of this appliance. In GB reference should be made to BS 5871 Part 2
and in IE reference should be made to the current edition of IS 813 “Domestic Gas
Installations” which makes clear the conditions that must be met to demonstrate that
sufficient ventilation is available.
4.3 The Atmosphere sensing device (ASD).
The appliance is fitted with an A.S.D (Atmosphere sensing device). If the appliance
closes down after a period of operation for no apparent reason, the consumer should
be informed to stop using the appliance until the installation and appliance have been
thoroughly checked. The A.S.D will shut the appliance down if an unacceptable
amount of harmful products of combustion accumulate. Under no circumstances
should the A.S.D be altered or bypassed in any way. Only a genuine manufacturer’s
replacement part should be fitted. The individual A.S.D components are not
replaceable.
4.4 Fireguard requirements.
A fireguard complying with BS 8423 should be fitted for the protection of young
children, the elderly, the infirm and pet animals.
4.5 Room considerations.
4.5.1 This appliance must not be installed in any room that contains a bath or shower
or where steam is regularly present.
4.5.2 An extractor fan may only be used in the same room as this appliance, or in any
area from which ventilation for the appliance is taken, if it does not affect the safe
performance of the appliance. Note the spillage test requirements detailed further on
in this manual. If the fan is likely to affect the appliance, the appliance must not be
installed unless the fan is permanently disconnected.
4.5.3 Note that soft wall coverings (e.g. embossed vinyl, etc.) are easily affected by
heat. They may scorch or become discoloured when close to a heating appliance.
Please bear this in mind when installing.
4.6 Chimney preparation.
4.6.1 If the appliance is intended to be installed to a chimney that was previously
used for solid fuel, the flue must be swept clean prior to installation. All flues should
be inspected for soundness and freedom from blockages.
4.6.2 Any chimney damper or restrictor should be removed. If removal is not possible,
they must be secured in the open position.
© GDC Group Ltd. 2012 Page 12
INSTALLE GUIDE

4.7 Fireplace preparation.
4.7.1 If the fireplace opening is an underfloor draught type, it must be sealed to stop
any draughts.
4.7.2 The fireplace floor should be reasonably flat to ensure that the convection box
can be installed without it rocking and so that a good seal can be made at the bottom
front of the box.
4.7.3 The front face of the fireplace should be reasonably flat over the area covered
by the convection box top and side flange seals to ensure good sealing. These faces
should be made good if necessary.
4.7.4 If the appliance is to be fitted against a wall
with combustible cladding, the cladding must be
removed from the area covered by the fascia. The
cladding must also not touch the fascia (See
figure 2). We suggest that the actual fascia is
used as a template to mark the area for
combustible cladding removal and that this area
is increased by at least 2mm all round.
4.7.5 If the fireplace opening is greater than the
acceptable dimensions given in this guide, do not
use the back of a fire surround or marble to
reduce the opening. This may cause cracking of
the surround back or marble.
4.8 The hearth and back panel.
The appliance must be mounted behind a non-
combustible hearth unless the conditions of
section 4.10.1.1 are met (N.B. conglomerate marble hearths are considered as non-
combustible). The appliance can be fitted to a purpose made proprietary class “O”-
150°C surround. The hearth material must be at least 12mm thick. The periphery of
the hearth (or fender) should be at least 50mm above floor level to discourage the
placing of carpets or rugs over it.
The appliance must not stand on combustible materials or carpets.
© GDC Group Ltd. 2012 Page 13
Figure 2
INSTALLE GUIDE

4.9 Fireplace clearances.
4.9.1 The minimum height from the base of the fireplace opening to the underside of
any shelf made from wood or other combustible materials is detailed below.
•For a she f up to 150mm deep: Minimum height = 700mm.
•For a she f deeper than 150mm: 700mm + 12.5mm for every 25mm depth over
150mm (See Figure 3).
© GDC Group Ltd. 2012 Page 14
Figure 3. Combustible shelf clearances
INSTALLE GUIDE

4.9.2 The minimum allowable distance from the outside of the appliance fascia to a
corner wall having combustible material or any other combustible surface which
projects beyond the front of the appliance is shown in figure 4. A 10mm access
clearance from a non-combustible surface is necessary at the left side.
© GDC Group Ltd. 2012 Page 15
Figure 4. (Dimensions are subject to manufacturing tolerances)
Key Description
Model
Bauhaus
A eight (mm) 614
B Width (mm) 515
C Depth into room (mm) 142
DMinimum mandatory clearance to combustible
surfaces projecting beyond the front of appliance (mm). 100
ERecommended clearance to non-combustible
surfaces for access purposes (mm). 50
INSTALLE GUIDE

4.10 Installation options.
In the United Kingdom, as supplied, the appliance can be installed in the following
situations: -
4.10.1 Conventional fireplace and hearth.
To a fireplace complete with hearth as shown in figure 5. Chair brick removal may not
be required providing at least 50mm clearance is available from the flue outlet to any
fireplace component.
4.10.1.1 ‘Hole-in-the-wall’ Installations.
-It is recommended that a hearth should be installed as in section 4.8 (See figure 5).
-If a reduced depth hearth is fitted, the fire must be installed so that the distance
from the base of the fireplace opening in the wall to the finished floor level is at
least 72mm. Where there is no floor covering or carpet and the floor is of a type
that is likely to be covered in such a way then the distance from the base of the
fireplace opening in the wall to the finished floor level should be increased to at
least 147mm. If the lower part of the fascia (the firefront) is free standing, the
recommended reduced hearth depth is 100mm. This is necessary to support the
firefront (See figure 4 for appliance dimensions).
-To protect from the risk of burns and ignition of clothing a tactile separator shall be
used. The hearth detailed in section 4.8 meets the requirements for a tactile
separator. If this is not used then a 590mm long fender, kerb, horizontal bar, or
other barrier, being fixed not less than 50mm above floor level and positioned
300mm in front of the fixing plane of the fire will meet the requirement.
© GDC Group Ltd. 2012 Page 16
Figure 5. earth and fireplace opening dimensions
INSTALLE GUIDE

4.10.2 Metal flue box and hearth.
The appliance can be installed to a fireplace incorporating a twin wall metal flue box
complying with the constructional requirements of the current edition of
BS 715 and with a flue conforming to BS EN 1856 part 1. The dimensions of the flue
box must conform to those shown in figure 6.
The top surface of the metal flue box and the upper 200mm of the sides and rear
faces must be covered with a 50mm layer of mineral wool or equivalent insulation
(See figure 6).
Important ote: Where the flue box has a base sheet that is single wall (i.e. a single
metal sheet) the flue box must be mounted on a non-combustible hearth. The hearth
material must be at least 12mm thick.
© GDC Group Ltd. 2012 Page 17
Figure 6. Metal flue box
INSTALLE GUIDE

© GDC Group Ltd. 2012 Page 18
4.10.3 Precast concrete or clay flue block system and hearth.
The appliance can be installed to a precast concrete or clay flue block system
conforming to BS1289 or BS EN 1858 with dimensions as in figure 7.
BS 1289 part 1 recommends there should be an air space or insulation between the
flue blocks and the plaster because heat transfer may cause cracking on directly
plastered flues. owever, generally this appliance is suitable for installations under all
circumstances unless there is a history of cracking problems. Remember that faults
such as cracking may be caused by poorly built and restrictive flues, e.g. mortar
extrusions, too many bends, flue heights below three metres, restrictive terminations
etc.
The appliance is suitable for installations conforming to older versions of BS1289 as
well as the current edition. The flue blocks must have a minimum width (Depth as you
look at the flue block when installed) not less than 63mm and a cross-sectional area
not less than 13,000mm2. Older editions of BS1289 required a cross-sectional area
of 13,000mm2. The current revision of the standard requires 16,500mm2. This
appliance is suitable in both cases. The total depth of the opening measured from the
finished front of the fireplace (Including plaster, surround etc.) must be 115mm.
Figure 7. Pre-cast Fireplace
INSTALLE GUIDE

4.11 Flues.
1. Suitable flues and minimum flue sizes are as follows:
It shou d be noted that, as with many app iances, sharp bends or horizonta runs in
meta f ues at the top of the system can be a cause of prob ems in these types of
insta ation.
-225mm x 225mm conventional brick flue.
-Single wall, twin wall or flexible flue liner with a minimum diameter of 125mm. The
materials to be used are stainless steel or aluminium as specified in
BS EN 1856 Part 1. The liner must be sealed to the surrounding area above the
fireplace opening and to the top of the chimney. An approved terminal must be
fitted.
-175mm diameter lined brick or stone flue.
-200mm diameter factory made insulated flue manufactured to BS4543 Part 2.
-175mm diameter flue pipe. See BS6461 Part 1 for suitable materials.
-A properly constructed precast concrete or clay flue system conforming to BS1289
or BS EN 1858. This system is only suitable if the conditions stated in section
4.10.3 are met.
2. The flue must conform to BS 5440: Part 1 in design and installation.
The flue, measured from the bottom of the fireplace opening to the bottom of the
terminal, shall be not less than 3m in actual vertical height. When calculated in
accordance with BS 5440: Part 1 Annex A, the minimum equivalent height of the flue
shall be 2.0m of 125mm dia. flue pipe.
3. The flue must not be used for any other appliance or application.
4. Proprietary terminals must comply with BS 715 or BS 1289. Any terminal or
termination must be positioned in accordance with BS 5440 Part 1 to ensure that the
products of combustion can be safely dispersed into the outside atmosphere. Where
the appliance is connected to an unlined brick chimney it is generally unnecessary for
the chimney pot to be replaced or for a terminal to be fitted unless the flue has a
diameter smaller than 170mm.
5. The flue must be completely sealed so that combustion products do not come into
contact with combustible materials outside the chimney.
© GDC Group Ltd. 2012 Page 19
INSTALLE GUIDE

5. PACK CONTENTS
The items required for this appliance are packed in sections.
Pack 1 - Fire unit contains:
1 eat engine.
1 ood
1 Loose parts pack including: -
1 Grommet for rear of convection box.
2 Strips of floor sealing tape.
6 Fibre / wooden plugs.
4 Wood screws.
2 Fire retaining cables.
2 Cable adjusters.
4 Eyebolts.
1 Length of self-adhesive foam seal.
1 Inlet “T” connector including pressure test point, nut and olive for 8mm inlet pipe.
1 Alkaline 9V PP3 battery.
1 Ceramic fuel effect pack (Not shown).
3 No.8 x 1/4 screws for securing the outlet baffle.
4 No.8 x 1/4 screws for securing the hood.
2 M4 x 25 screws for securing the fascia.
2 Washers for securing the fascia.
1 Smoke match tube.
1 Outlet baffle.
1 Control knob.
2 M4 x 7mm screws for securing the control knob.
Pack 2 - Fire front contains:
1 Fascia
1 Firefront casting
1 Front cover casting.
1 Rear screen assembly.
2 Screws
Remove all the items carefully to prevent damage. Take special care when handling
the ceramic components. Some items may be contained in the packaging fitments -
Examine the packaging carefully before discarding. Check that all the items are
present and undamaged.
© GDC Group Ltd. 2012 Page 20
INSTALLE GUIDE