Wonderfire AF 18XL User guide

AIRFLAME EXCEL MK.3
AF 18XL 9500360
AC 18XL 9500361
INSTALLATION & SERVICING
MANUAL
Patent applied for
600B683/01
Please leave these Instructions with the user
This Appliance is for use in the United Kingdom (GB) and the Republic
of Ireland (IE) only.

2
IMPORTANT NOTES
If your Wonderfire Airflame Excel Mk.3 burner is to be installed within a mk.3 Wonderfire
convector box, then this manual should be read in conjunction with the convector box
installation manual (part number 9860371). This appliance is intended for decorative purposes.
Under no circumstances must rubbish or debris of any description be thrown onto the fuel
bed.
Please read the following section before commencing with installation.
Before installation, ensure that the local distribution conditions (identification of the type of
gas and pressure) and the adjustment of the appliance are compatible.
It is the law that competent persons, in accordance with the Gas Safety (Installation and Use)
(amendment) Regulations 1994, install all gas appliances.
Improper installation of this decorative open gas fire could be hazardous to health. This fire is
to be used only in a properly flued, incombustible, masonry fireplace with the chimney or flue
free of any obstruction or damper. If in doubt consult building regulations or a supplier.
This appliance must be installed in accordance with the rules in force.
The flue must be swept before installation.
This appliance must be fitted in a fireplace opening conforming to BS 1251.
A flue with a minimum diameter of 7”, a minimum effective height of 3 metres, with a good
upward draught is required for fires operating within standard fireplace openings. Larger
fireplace openings may require a correspondingly larger chimney diameter, a faulty flue or
chimney may result in products of combustion spilling into the room with consequent possible
damage to furniture and decor. Conduct a smoke test before proceeding with installation.
GB only: A permanent ventilation grille of fixed design and having a minimum free area of
100cm2must be fitted with direct access to outside air to room.
Note: see convector instructions if being installed within a Wonderfire convector box for
ventilation requirements.
IE only: This appliance must be installed in accordance with IS 813 1996 (as amended).
We strongly recommend the use of an approved fireguard whenever the elderly, infirm or
young children are in the presence of a working fire.
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.
RELATED DOCUMENTS:
Gas Safety (Installation and Use) Regulations 1994 (as amended) BS 5440 Part 1 1990
BS 5871 Pt 3 Installation of Decorative Fuel Effect Fires BS 5440 Part 2 1989
Fireplace components conforming to BS 1251 assembled BS 5871 Part 3 1990
in accordance With BS 8303-1986 BS 6461 Part 1 1984
Relevant Building Regulations BS 6461 Part 2 1984
Republic of Ireland: IS 813 1996 (as amended)

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CONTENTS
Check contents before proceeding with the installation of your Wonderfire
1. 1 x Burner Assembly
2. 1 x Two-piece front Coal
3. 1 x Ceramic Fuel Matrix
4. 1 x Set of Dress Coals
5. 1 x User instructions
6. 1 x Installation Instructions
7. 1 x Guarantee card
8. 1 x Loose parts pack (containing 1 x fixing screw and 1 x fibre rawlplug)
9. 1 x Smoke match tube
TECHNICAL DATA
Heat inputs (gross) :
AF18XL AF18XLP **
Minimum 5.8kW 7.6kW
Maximum 10.5kW 9.0kW
Setting pressures:
AF18XL AF18XLP **
Maximum (cold) 13.75mbar ± 0.75 mbar 35.0mbar ± 0.75 mbar
Injector sizes:
AF18XL AF18XLP **
82-722 92-260
Supply pressures:
Natural gas (G20) 20mbar
Propane (G31) 37mbar
Burner tray dimensions:
Width 430mm (17”) at front tapering to 300mm(11¾”) at rear
Depth 225mm (9”)
Height (including dress coals) 295mm (11½”)
** When converted using kit number 9500362

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INSTALLATION AND COMMISSIONING INSTRUCTIONS
PLEASE READ CAREFULLY BEFORE STARTING WORK
Fireplace, flue and ventilation
details
Read the important notes on the
inside front cover before
proceeding with the installation of
your fire. Only when you have
complied with all of the above
should you commence with the
installation of the appliance.
NOTE: Hearth requirements in
Figure 1. The appliance must be
mounted behind a non-combustible
hearth (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 surface of the hearth must be sufficiently flat to enable the bottom of the front
surround and the bottom front cover to be aligned horizontally. Any excessive
unevenness (uneven tiles, Cotswold stone, etc.) should be rectified.
The appliance must not stand on combustible materials or carpets.
The minimum height from the top
surface of the hearth to the underside of
any shelf made from wood or other
combustible materials is as follows:-
• For a shelf up to 150mm deep :
Minimum height = 818mm.
• For a shelf deeper than 150mm :
818mm + 12.5mm for every 25mm
depth over 150mm.
Burner Position
The burner (figure 2) is produced from
a soft ceramic material and should be handled carefully.
Remove all packaging material from the burner, and inspect for any signs of
mishandling which may affect the performance. There are two sets of burner ports.
One set are located on the top face of the burner, and the other, on the front face.
Each unit is flame tested before it leaves the factory, and as a result, some slight
discoloration may be evident around the burner ports. There may also be some slight
surface cracking evident on the burner, which is completely normal and is not
detrimental to performance. The burner is retained by two clamps and set in position
before it leaves the factory. Check that the injector is aligned straight and central to
the venturi. Check that the pilot unit is clear of the front face of the burner by 2-4mm.
Figure 2
Figure 1

5
Figure 3
Figure 4
8mm (5/16) Bundy or semi-rigid tubing must be used to connect the appliance to the
gas supply.
Centre the burner tray in the fireplace opening with the tray as far to the rear as
possible. Secure the burner in position and fix through the centre front leg into the
hearth using a heatproof wall plug and
fixing screw (supplied). Purge the gas
supply and make the connection to the
control. Test all joints for gas soundness.
Attach a manometer to the pressure test
point (see figure 2a) and follow the lighting
procedure to establish the pilot and then
turn to maximum setting. Check the gas
pressure against the setting pressures
(see gas data).
Turn off the fire and allow to cool.
COMMISIONING THE BURNER
Placing the front coal
Remove both front coal pieces from the protective packaging and position in front of
the burner as shown in figure 3.
The retaining tags may be adjusted
in order to ensure secure fitting of
the front coal.
Placing the fuel matrix
Remove the fuel matrix from its
protective packaging and position
on top of the burner as shown in
figure 4. The rear face of the burner
should locate into two cut-outs on
the top face of the rear legs. Ensure
that the matrix sits flatly on the top
of the burner.
Figure
2a

6
Figure 6
Figure 5
Figure 7
Figure 8
Placing the dress coals
Open the loose coals to find two
further bags. These contain:
•6 x Finger coals
•18 x Random cut coals
Open the bags and keep the different
types of coals separate. Begin the
coal build by placing six random
shaped coals as shown in figure 5,
ensuring that they form a bridge
between the front coal and the coal
matrix. In order to get the best flame
effect, it is important that the coals
are evenly spaced, and sit 10-15mm
from each other.
Next, take five random shaped coals
and position as shown in figure 6.
This second row of coals should rest
on top of the first row, overlapping by
5-10mm. Again, ensure even spacing
to obtain the best flame effect.
Now take four more random shaped
coals and position as shown in figure
7 to make the third row. These coals
should again overlap the previous
row by about 5mm. Ensure even
spacing between coals.

7
Placing the dress coals (cont).
Finally, take the three remaining
random shaped coals. Place one
in the centre of the matrix
(position ‘a’), place the other two
next to it (position ‘b’) as shown in
figure 9. To complete, place the
two remaining finger coals along
the back of the matrix (position
‘c’) also shown in figure 9.
OPERATION OF THE FIRE
This fire is controlled by a four position gas tap mounted in the front of the appliance.
In addition to the OFF setting there is a pilot position and two heat control settings.
To Light the Pilot
Ensure that the control knob is turned to the OFF position. Depress the control knob
and turn anticlockwise until the IGNITION position is reached, continue turning the
knob to activate the piezo ignition. Two ‘clicks’ will be observed, and the pilot should
ignite. Hold the knob in this position (keeping it depressed) for ten seconds to allow
the flame supervision device to establish.
Observe if it is alight by looking through the slots to the left hand end of the front
coals.
If the pilot does not light immediately, repeat the above procedure, keeping the knob
depressed for several seconds in order to purge any air from the system.
If after ten seconds, ignition has not occurred, turn the control knob back to the OFF
position and repeat the ignition procedure after 30 seconds.
Once the pilot is lit, keep the control knob depressed for ten seconds to allow the
flame supervision device to establish.
When the control knob is released, the pilot should remain lit. If the pilot fails to
remain lit, repeat the ignition procedure, this time keeping the control knob
depressed for a longer period of time.
Figure 9
‘c’ ‘c’‘b’ ‘b’
‘a’

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Operation of the fire – continued
Lighting the Main Burner
Once the pilot light is established the main burner can be lit by turning the control
knob anticlockwise to the HIGH position.
Controlling the heat setting.
In order to change from one setting to another depress the control knob slightly and
turn the knob to the required position. Alternatively, if a setting between LOW and
HIGH is required, then the control knob may be turned to this position.
Note: We recommend you use the appliance at a low setting for the first few hours of
use to reduce the thermal cracking of the surface of the burner.
Surface cracking of the burner is normal and is no cause for concern. Whist binding
materials are being burnt out of the burner there may be a slight odour.
To Turn the Fire back to Pilot Setting
Depress control knob and turn clockwise until pilot setting is reached.
To Turn the Fire OFF Ensure control knob is in pilot position, depress control knob
and turn clockwise to the OFF position.
For fires fitted with Aeration control
To operate the aeration control system, the following procedure should be followed:
•Allow the appliance to warm up, (for at least fifteen minutes) in the fully aerated
position, with the control lever pushed in to the locked position – see figure 10.
•Switch to the minimum
aerated position by slightly
lifting the control lever. A
spring mechanism will close
the aeration shutter.
•To return to the fully aerated
position push the control
lever in and slightly
downwards until it rests in its
locked position.
Please note : It is advisable to run the fire in its fully aerated mode (control knob
pushed in) at the beginning of each operation and if running at the minimum rate
setting, or to burn off any carbon deposits which may have built up after prolonged
use of the minimum aerated setting.
Figure 10

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CLEARANCE TEST
Note : this test is to be conducted with the
firefront in position. Warm up the appliance
on MAX for ten minutes. Insert a smoke
match tube as shown in figure 11, 30mm from
either side of the fireplace opening, Smoke
should be drawn positively into the appliance.
If not repeat the test after a further fifteen
minutes. If smoke is still not positively drawn
into the appliance, isolate the gas supply to
the appliance and seek expert advice.
SERVICING AND MAINTENANCE
See convector instructions if your Airflame Excel mk.3 burner is installed within a
Wonderfire convector box.
Annual maintenance
The
The coals should be removed and any sooting carefully brushed from the surface
with a soft brush.
The coal matrix should be removed and any debris shaken off. The burner should be
removed from the fireplace and any debris carefully removed using a soft brush.
Inspect the burner for any damage and repair or replace if necessary. Please note
surface cracking of the burner is quite normal.
Check the venturi and injector for linting and clean if necessary. Clean any debris or
carbon from around the pilot unit and check the correct operation of the gas control.
Reinstate the burner into the fireplace, reconnect the gas supply and check the
soundness of all gas connections. Refit the coals in accordance with the section of
this manual entitled, “Commissioning the burner”.
Follow the lighting procedure and check for spillage. If spillage is found the cause
should be identified and remedied.
Check any purpose made room ventilation is free from obstruction.
NEVER ATTEMPT TO INSPECT OR REMOVE THE FIRE UNLESS IT HAS BEEN
ALLOWED TO COOL FOR AT LEAST 15 MINUTES
The following procedures should be carried out with these tools at hand.
Slot head screwdriver 14mm spanner
7mm spanner 15mm spanner
10mm spanner 16mm spanner
11mm spanner 3/4 AF spanner
12mm spanner Phillips No.2 type screwdriver
External circlip pliers
Figure 11

10
Before servicing the component parts carry out the following procedure:
1. Turn off the appliance and wait least 15 minutes to allow the fire to cool.
2. Isolate the gas supply.
3. Remove the coals, matrix and front coal.
4. Disconnect the inlet supply/appliance union.
5. Unscrew the appliance fixing screw.
6. Remove the appliance.
To remove the injector:
Carefully invert the burner assembly ensuring that the ceramic surfaces are not
damaged. Disconnect the injector/supply pipe union, place the burner assembly
upright. Remove the injector. Replace in reverse order.
To remove the Piezo unit:
The piezo unit is an integral part of the gas tap : Refer to section ‘To remove gas tap’.
With the gas tap removed, remove the external circlip that retains the piezo unit.
Remove the piezo unit from the tap. Replace in reverse order.
To remove the thermocouple/pilot unit:
The thermocouple is an integral part of the pilot unit, and must be replaced as such.
To remove the pilot unit, disconnect the pilot gas feed pipe at the union with the pilot
elbow, disconnect the H.T. lead from the pilot unit. Disconnect the thermocouple from
the gas tap. To detach the unit from the burner, first remove the screw securing the
dust cage to the pilot/burner. Carefully remove the dust cage and place aside.
Remove the second retaining screw and withdraw the pilot unit. Replace in reverse
order.
To remove the gas tap/F.S.D.
Invert the burner assembly, disconnect the inlet pipe union, pilot supply union,
manifold pipe union, H.T. lead, and thermocouple connecting nut from the tap end.
Remove control knob, remove the retaining nut. Replace in reverse order.

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FAULT FINDING CHART
Problem Remedy
Pilot light will not light when
ignition button is pressed.
1. Check that the lighting instructions are being followed.
2. Check that the spark is jumping between the electrode
and the pilot head. If not, check for debris around the
electrode, condition of the wiring and any possible short
circuit.
3. Check that the gas is passing through the pilot injector.
If not, check pipe, injector and tap for possible blockage
and rectify.
4. Purge the system.
Pilot light ignites, but will not
establish after holding the tap
knob in for ten seconds.
1. Ensure that the pilot flame is impinging on the
thermocouple probe.
2. Check that the thermocouple buts are tight on both the
tap and the pilot unit assembly.
3. If steps 1) and 2) do not cure the problem it is likely that
the thermocouple is faulty. Remove and replace.
Fire operates well, but ‘pops’. 1. Popping is usually caused by the coals being placed to
closely together. Ensure that the coal arrangement
instructions given in this manual have been followed
precisely.
2. If the injector has been removed or disturbed during the
installation, ensure that the compression joint has been
assembled correctly and is gas tight.
Excessive sooting. A small amount of sooting can occur on any fire of this type,
especially those operating on LPG.
1. Excessive sooting can be caused by incorrect
arrangement of the coals. Ensure that the coal
arrangement instructions given in this manual have
been followed precisely.
2. The position of the injector is set in the factory, but if
this has been disturbed during installation, then it
should be reset. The correct position is when the
injector points directly down the centre of the venturi. A
blue flame with yellow tips should be produced in this
position.
3. Check the flue pull. A ‘lazy’ chimney will not exhaust all
of the soot particles from the burner.
4. Prolonged use of the minimum aeration setting on
models with adjustable aeration. Return to the full
aeration setting after cleaning.
Fire glows, but little or no flame
is produced.
This type of fire is designed to be efficient, and produce
radiant heat in favour of expensive flames. The flames that
are produced are 40-60mm long. If the flames are
significanly shorter than this after the fire has been allowed
to burn on MAX for 30 minutes, check the following.
1. Ensure that the injector is clear from obstruction.
2. Ensure that the correct injector is fitted (see gas data).
3. Measure the gas pressures with the fire operating at
MAX setting. The reading at the pressure test point
should be as laid down in the gas data section of this
manual. If the pressure is low, check the gas run for
kinks, fiction producing fittings etc. Do not install more
than 1.2 metres of 8mm gas line with natural gas fires.
4. Check that any restrictor elbow is fully open.

12
Figure 12
NOTE: ALWAYS USE GENUINE WONDERFIRE
SPARE PARTS
THIS APPLIANCE IS NOT SUPPLIED WITH A DECORATIVE FIREFRONT.
A SLOTTED FIREFRONT WITH A MINIMUM FREE AREA AS SHOWN IN FIGURE 12
MUST ALWAYS BE USED.
SHORT SPARES LIST
Never fit non-standard parts as this may invalidate the warranty.
Use only genuine Wonderfire replacement parts.
Use only the correct number of fibre bed components and install them as described
in the procedures.
Description Wonderfire Part number
Gas tap 9730084
Main injector (AF18XL) 9730091
Main injector (AF18XLP) 9730007
Pilot unit (NG) 9740029
Pilot unit (LPG) 9740030
Ceramic burner 9530042
Front coal 9770100
Coal matrix 9770099
Pack of dress coals 9780050
Lint guard/dust cage 0567619
Piezo Unit 0525339
Manufactured by Wonderfire ©1999
As our policy is one of continuous development, some details given in this manual may be subject to change.
Fig 12