Wonderfire Gasflame 3 639 GFC Assembly instructions

Gasflame 3
Convector Box
MODEL 639 GFC
Inset Decorative
Gas Fire
(G.C No. 32-815-81)
INSTALLER’S GUIDE
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20)
WHEN CONVERTED USING CONVERSION KIT NO. 0591301 THIS
APPLIANCE IS FOR USE WITH PROPANE GAS (G31)
THIS APPLIANCE IS FOR USE IN THE UNITED KINGDOM (GB) AND
THE REPUBLIC OF IRELAND (IE) ONLY.
We trust that these instructions give sufficient details to enable this appliance to
be installed and maintained satisfactorily. However, if further information is
required, our Wonderfire Technical Helpline will be pleased to help.
Please telephone [phone]
INSTALLER: Please leave this guide with the owner
© Wonderfire
3003043/01

INSTALLER’S GUIDE
Page 1
Safety First.
Wonderfire fires are CE Approved and designed to meet the appropriate British
Standards and Safety Marks.
Quality and Excellence.
At the heart of every Wonderfire fire.
All Wonderfire 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 the Society of British Gas Industries which works to
ensure high standards of safety, quality and performance.
Careful Installation
Wonderfire is a CORGI registered company. All our gas fires must be
installed by a competent CORGI Registered Installer in accordance
with our Installer Guide and should not be fitted directly on to a
carpet or floor of combustible material.
Wonderfire, Wood Lane, Erdington, Birmingham B24 9QP
www.wonderfire.co.uk
Because our policy is one of constant development and improvement, details may vary
slightly from those given in this publication.

INSTALLER’S GUIDE
Page 2
CONTENTS
1. SAFETY .......................................................................................................2
2. LIST OF ACCESSORIES..........................................................................3
3. GENERAL INSTALLATION REQUIREMENTS.................................4
4. UNPACKING .............................................................................................. 9
5. INSTALLATION OF APPLIANCE.........................................................9
5.1 Fireplace size.................................................................................................9
5.2 Fireplace flue pull. ........................................................................................ 9
5.3 Installing the convector box........................................................................10
5.3.1 Fitting the foam seals ..................................................................................10
5.3.2 The Flue restrictor.......................................................................................10
5.3.3 Fitting the cable retainers............................................................................11
5.4 Installation of the model 639 burner unit ...................................................13
5.4.2 Locating the burner. ....................................................................................13
5.5 Burner and supply pipe installation ............................................................13
5.6 Ceramic fuel bed Installation......................................................................13
5.7 Spillage check. ............................................................................................14
1. SAFETY
Installer
•Before continuing any further with the installation of this appliance please read
the following guide to manual handling
•The lifting weight of this appliance is 9.6 kg. 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.

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2. LIST OF ACCESSORIES
Description Part number
Aspire trims with firefronts
Satin Chrome effect 9820111
Brass effect 9820112
Black 9820113
Copper effect 9820114
Bauhaus Firefront (Fret)
Polished Brass effect 16in 9800121
Satin Chrome effect 16in 9800122
Charcoal Black 16in 9800123
Blenheim Firefront (Fret)
Brass effect 16in 9800040
Antique (Black & Brass effect) 16in 9800075
Chrome effect 16in 9800076
Black Cast Iron with Brass Finials 16in 9800039
Decorative trims
Chrome effect full trim 16in 9820055
Brass effect full trim 16in 9820045
Black full trim 16in 9820060
Brass effect half trim 16in 9820050
Chrome effect half trim 16in 9820100
Oversized brass effect trim 16in 9820048
LPG Conversion kit 0591301

INSTALLER’S GUIDE
Page 4
3. GENERAL INSTALLATION REQUIREMENTS
3.1 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. The Council for the Registration of Gas
Installers (CORGI) requires its members to work to recognised standards.
In the United Kingdom the installation must also be in accordance with:
a) All the relevant parts of local regulations.
b)All relevant codes of practice.
c) The relevant parts of the current editions of the following British Standards:-
BS 1251
BS 4543 Part 2
BS 5440 Part 1
BS 5440 Part 2
BS 5871 Part 3
BS 6461 Part 1
BS 6891
BS 8303
d)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 also conform
with the relevant parts of:
The current editions of:-
3IS 813
3ICP3
3IS327
b)All relevant national and local rules in force.
c) As supplied the appliance can be installed in the following situations: -
3.2 To a fireplace complete with surround and hearth as shown in figure 1 and
complying with BS1251. The required fireplace, hearth, and clearance dimensions
are shown in figure 1. (Remove any firebrick back and existing heating appliance).

INSTALLER’S GUIDE
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Suitable flues and minimum flue sizes are as follows: -
a) 225mm x 225mm conventional brick flue.
b) 175mm diameter lined brick or stone flue.
c) 200mm diameter factory made insulated flue manufactured to BS4543.
d) 175mm diameter flue pipe. See BS6461 Part 1 for suitable materials.
e) A masonry chimney having a correctly installed flexible flue liner with
minimum diameter of 125mm and conforming to BS715.
The minimum effective height of the flue must be 3m.
The flue must not be used for any other appliance or application.
Any chimney damper or restrictor should be removed. If removal is not possible,
they must be secured in the open position.
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.
Figure 1. Hearth and Fireplace Opening

INSTALLER’S GUIDE
Page 6
3.3 If the fireplace opening is an underfloor draught type, it must be sealed to
stop any draughts.
3.4 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 minimum class “O” – 100°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 (See figure 1).
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 base of the
fireplace opening must be level with the top surface of the hearth. There
should be no gaps between the hearth and the fireplace opening.
3.4.1 ‘Hole-in-the-wall’ Installations
•It is recommended that a hearth should be installed as in figure 1.
•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
85mm minimum. It is recommended that the reduced hearth has a depth from the
fixing plane of the fire of 100mm minimum. This is necessary to support the
lower front casting.
3.5 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
3.6 The appliance must not stand on combustible materials or carpets.

INSTALLER’S GUIDE
Page 7
3.7 The minimum height from the top 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 = 700mm.
•For a shelf deeper than 150mm
700mm + 12.5mm for every 25mm depth over 150mm
(See Graph 1).
3.8 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.
3.9 This appliance must not be installed in any room that contains a bath or
shower or where steam is regularly present.
3.10 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.
Graph 1. Combustible shelf clearances.

INSTALLER’S GUIDE
Page 8
3.11 Normal advantageous ventilation is usually sufficient to satisfy the ventilation
requirements of this appliance. In GB references should be made to BS 5871 Part 2
and in IE reference should be made to the current edition of IS 813 which makes
clear the conditions that must be met to demonstrate that sufficient ventilation is
available.
3.12 Propane gas appliances must
not be installed in a room that is
built entirely below ground level
(see BS 5871 Part 3).
3.13 If the appliance is to be fitted
against a wall with combustible
cladding, the cladding must be
removed from the area covered by
the outer surround. The cladding
must not touch the surround (See
figure 2). We suggest that the
appliance fitted with the surround is
used as a template to mark the area
for combustible cladding to be
removed and that this area is
Figure 3. Appliance Clearances.
Figure 2. Removal of Combustible
cladding

INSTALLER’S GUIDE
Page 9
increased by 2mm all round.
3.14 Combustible side projections up to 75mm forward of the fixing plane of the
fire are to be a minimum of 125mm from the fireplace opening (See figure 3)
3.14.1 Combustible side projections greater than 75mm forward of the fixing plane
of the fire are to be a minimum of 250mm from the fireplace opening (See figure
3).
3.14.2 Non-combustible side projections to be 75mm from the fireplace opening
(See figure 3)
4. UNPACKING
Contents: -
1 Convector box assembly
1Accessory kit including: -
4 Lengths of Self Adhesive Foam seal
2 Eyebolts
2 Fibre wall plugs
2Retaining cables
2Cable clamps
1Restrictor plate
1 Stainless steel screw
Check that all the listed parts are present and in good condition.
5. INSTALLATION OF APPLIANCE
5.1 Fireplace size
The fireplace must comply with the requirements described in section 3.
5.2 Fireplace flue pull.
Visually inspect the flue for any obstruction, and that a smooth transition from the
fireplace opening into the flue is available. Close all doors and windows in the room in
which the appliance is to be installed. After confirming with a match that smoke is
drawn into the flue, light a 13 gram smoke pellet and check that there is a definite flow
through the flue. Verify outside that the smoke exits from one terminal only and that
the termination is suitable. Observe, where possible, upstairs rooms and loft spaces for
signs of escaping smoke indicating a defective flue. If there is not a definite flow warm
the flue for a few minutes and repeat the smoke pellet test. If there is still no definite

INSTALLER’S GUIDE
Page 10
Figure 6. Flue restrictor
Figure 5. Floor Sealing
flow the flue may need remedial work
– Do not fit the appliance until there
is a definite flow through the flue.
5.3 Installing the convector box
5.3.1 Fitting the foam seals
1. Supplied with this appliance are
four lengths of self-adhesive foam
seal. Position three of the foam seals at
the rear of the appliance front flange.
Cut the adhesive foam seal to length.
Be careful not to stretch the foam
seal when positioning or cutting.
Remove the backing paper and locate
the adhesive foam seal to the rear of the appliance
front flange (see figure 4). It is important that there
are no gaps between the joints.
2. Position the remaining length of foam seal along
the front edge of the base. Make sure that the whole
length of the front edge of the convector box is fully
sealed (See figure 5).
5.3.2 The Flue restrictor
This appliance is supplied with a flue restrictor for
use where the flue draught is excessive. The restrictor
must NOT be fitted where a
flue liner is used. For all
other installations the
restrictor should be fitted.
There may however, be
certain exceptional
circumstances where fitting
the restrictor causes the fire
to fail the spillage test. In
such cases the restrictor will
have to be removed. After
removal conduct the spillage
check again.
The restrictor is supplied
Figure 4 Fitting the foam seal

INSTALLER’S GUIDE
Page 11
Figure 8. Cable Routing
Figure 7. Eyebolt Positions
loose and is fixed with a
stainless steel machine screw
supplied. See figure 6.
Before continuing with the
installation consideration
must be made given to the
supply pipe. See section 5.5
5.3.3 Fitting the cable
retainers
1. Make sure that the relevant areas at the
fireplace back or floor are sound enough to
take the eyebolts. If these areas have
deteriorated due to prolonged use they should
be made sound with a suitable cement.
2. Drill two holes in the rear wall of the
fireplace for the eyebolt plugs. The holes
should be drilled within the range of positions
shown in figure 7 using a no.12 masonry drill.
The holes should be equidistant each side of
the centre line of the fireplace to ensure that the
appliance finishes centrally in the opening
when tension is applied to the cables.
3. Insert a fibre plug into each hole. Use the
fibre plugs supplied with this appliance - Never use plastic plugs instead of the fibre
plugs supplied. Screw the eyebolts into the plugs. Make sure that the bolts are secure.
4. Place the convector box close to the fireplace but allow sufficient access into the
fireplace opening so that the cables can be threaded through the eyebolts and returned
through the back of the convector box. If a concealed connection is being used, insert
the convector box into the fireplace feeding the supply pipe through the pierced hole in
the rear / side grommet(s).
5. The convector box has a debris deflector. There are two small holes in both sides of
the debris deflector. Insert one end of each cable (one cable each side) through the
lower of the two holes and return the end through the upper of the holes. See figure 8.
Give the cables a pull so that they are secure.

INSTALLER’S GUIDE
Page 12
Figure 11. Fitting the coal support plate
Figure 10. Lower Cable Retention
Figure 9. Cable Route
6. Thread the cables through the eyebolts. Return
the cables through the holes near the bottom of the
convector box back panel, and through the “V”
shaped brackets near the bottom front sides of the
convector box - See figure 9.
7. Place the convector box fully back into the
fireplace opening so that it is sealed against the
fireplace front.
8. Fit a cable retainer over the bottom end of each
cable.
9. Pull each cable taut. Push the cable retainers
hard up against the “V” brackets. Tighten the
screws in the retainers so that they clamp the cables
in position. Apply tension to the cables by turning
the hexagonal adjusters by hand. See figure 10.
10. Inspect the installation of the convector box
against the fireplace surround. If the
convector box is aligned squarely
and the sealing is satisfactory, fully
tighten the cable retainers.
11. If the convector box is not
correctly aligned, release the tension
on the cables by slackening the
screws and turning the hexagonal
adjusters fully anticlockwise. The
convector box should then
automatically realign itself. Pull each
cable taut again and push the cable
retainers back against the “V”
brackets. Again, tighten the screws in
the retainers and apply tension to the
cables by turning the hexagonal
adjusters clockwise as far as possible.
12. Feed the free length of the cables
into the gap above the brackets so that
they are available to allow easy
removal and refitting of the appliance
during subsequent service calls. Do
not cut off the free lengths of cable

INSTALLER’S GUIDE
Page 13
5.4 Installation of the model 639 burner unit
5.4.1 Prior to installation of the
burner the coal matrix support plate
must be fitted (See figure 11). Two
self-tapping screws retain the plate.
5.4.2 Locating the burner.
There is a bracket on the front
support leg of the model 639 gas fire
which can be removed and disposed
of. Keep the screw as this is required
for securing the burner unit to the
bracket at the base of the convection box.
•Place the burner assembly in position against the convector box bottom location
bracket. See figure 12).
•Secure using the screw removed previously.
5.5 Burner and supply pipe installation
There are three grommets to allow supply pipe passage into the convector box. First
decide which grommet is to be used. Do not remove the grommets. Pierce the
grommet to allow the pipe to pass through it. The grommet should envelop the pipe. If
the hole is larger than the pipe, seal it with tape. Do not pierce the grommet unless the
supply pipe is to pass through it. Refer to model 639 installer’s guide.
5.6 Ceramic fuel bed Installation
Follow model 639 installer’s guide.
Figure 12. Locating the burner

INSTALLER’S GUIDE
Page 14
5.7 Spillage check.
•A spillage check must be
made before leaving the
installed appliance with
the customer. Make this
with all the ceramic fuel
effect pieces and
firefronts / castings in
position. (See figure 13 )
•Close all doors and
windows in the room
containing the appliance.
Light the appliance and
set the control to the
‘HIGH’ position. Leave
the appliance on for five
minutes. See lighting
instructions within model
639 installer’s guide.
•Insert the smoke match 40mm away from the side of the canopy and 20mm from
the top of the underside of the canopy. The end of the smoke match should be level
with the front face of the fireplace opening.
•The installation is satisfactory if the smoke is drawn into the fireplace opening. If
the smoke is not drawn into the fireplace opening, leave the appliance alight at the
maximum setting for a further ten minutes and then repeat the test. If smoke is still
not drawn into the appliance disconnect the appliance and seek expert advice.
•If the above test is satisfactory, open all internal connecting doors, hatches, etc. in
the room. Keep all doors and windows that open to the outside of the building
closed. Switch on any extractor fan installed in the same room as the appliance or a
connecting room. Open all doors and other openings between the fan and the
appliance. Recheck for spillage as above. If the smoke is drawn into the appliance,
continue with the installation. If the test is not satisfactory, disconnect the
appliance and advise the customer of the cause of failure.
5.8 Advise the customer to refer to the model 639 Owner’s guide for operating
and maintenance guidelines.
Figure 13. Spillage check