Baxi GALLERY 661 Installer's Manual

5114794/01

INSTALLER GUIDE

owner

THIS APPLIANCE IS SUITABLE ONLY FOR INSTALLATION IN THE UNITED

For technical advice firstly contact your retailer. If further advice is required then call

Model 661

Heat Engine

POWER FLUE INSET GAS FIRE

(GC No. 32-810-15)

THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20).

WHEN CONVERTED USING CONVERSION KIT NO. 0595221 THIS

APPLIANCE IS FOR USE WITH PROPANE GAS (G31).

KINGDOM (GB) AND THE REPUBLIC OF IRELAND (IE).

0161703 8157 for The Midlands and North or

01462 813 138 for The South.

INSTALLER: Please leave this guide with the

© Baxi Heating U.K. Ltd.

This gas fire is CE Approved and designed to meet the appropriate British Standards

This fire has been manufactured to the highest standards of quality and excellence and

was manufactured under a BS EN ISO 9001 quality system accepted by the British

The manufacturer is a member of the Society of British Gas Industries which works to

Because our policy is one of constant development and improvement, details may vary slightly from those

INSTALLER GUIDE

Safety First.

and Safety Marks.

Quality and Excellence.

Standards Institute.

The Highest Standards

ensure high standards of safety, quality and performance.

Careful Installation

The manufacturer is a CORGI registered company. This gas fire 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.

Baxi Fires Division, Erdington, Birmingham B24 9QP

given in this publication

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INSTALLER GUIDE

CONTENTS

Section Heading Page

1. SAFETY 4

2. APPLIANCE DATA 4

3. GENERAL INSTALLATION REQUIREMENTS 5

4. APPLIANCE DIMENSIONS 12

5. UNPACKING 14

6. PREPARING FOR INSTALLATION 16

7. WALL PREPARATION 16

7.1 General. 16

7.2 Brick, stone etc. building. Main case in front of wall 17

7.3 Brick, stone etc. building. Main case recessed into wall. 17

7.4 Lintel installation. 18

7.5 Timber frame building. Firebox in front of wall. 19

7.6 Wall preparation for flue tube. 19

7.7 Core drilling. 19

7.8 Hammer and chisel cutting. 19

7.9 Combustible walls (wood, fibreboard, plasterboard etc.). 20

7.10 Fixing the appliance in position. 21

7.11 Prepare flue assembly. 22

8. INSTALLATION OF ELECTRICS, FIREBOX AND FAN BOX 22

8.1 Fan box installation preparation. 23

8.2 Securing firebox to wall - cable retention. 24

8.3 Securing firebox to wall using fixing brackets. 25

8.4 Completing the fan box installation. 25

8.5 Electrical installation. 26

8.6 Refitting the burner unit. 26

8.7 Electrical test. 26

8.8 Terminal guarding. 27

9. GAS SUPPLY INSTALLATION 27

9.1 Gas supply connection. 27

9.2 Preliminary burner checks. 28

9.3 Check inlet pressure . 29

9.4 Fitting the burner tray trim. 29

10. FITTING THE CERAMICS 29

11. FITTING THE FASCIA AND FIREFRONT 30

12. CHECKS 30

13. FINAL REVIEW 32

14. SERVICING PARTS AND REPLACEMENT 32

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When lifting always keep your back straight. Bend your legs and not your back.

Always grip with the palm of the hand. Do not use the tips of fingers for support.

silicate fibres. Excessive exposure to these materials may cause irritation to eyes,

handling these articles to ensure that the release of dust is kept to a minimum. To

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. This is not classified as “hazardous waste” and

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

INSTALLER GUIDE

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 as below: -

Heat Engine (kg) Fan Box (kg)

7.5 6.0

! One person should be sufficient to lift the fire. If for any reason this weight is

considered too heavy then obtain assistance.

!

! 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 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.

2. APPLIANCE DATA

This product uses fuel effect pieces and a burner compartment rear wall
containing Refractory Ceramic Fibres (RCF), which are man-made vitreous

skin and respiratory tract. Consequently, it is important to take care when

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

may be disposed of at a tipping site licensed for the disposal of industrial waste.

area and always wash your hands before eating or drinking.
This appliance does not contain any component manufactured from asbestos or
asbestos related products.

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The appliance data label is located on a plate at the base of the fire. This can be seen by

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

In the United Kingdom, all electrical supply installation must be installed in accordance

Environment and the Welsh Office or the Building Standards (Scotland) (Consolidation)

INSTALLER GUIDE

3.15kW (10,748Btu/h)

37.0 ± 1.0 mbar (14.85 ±

21500/189 fitted with RBM

Piezo Electric. Integral with

Gas

Inlet Pressure 20mbar 37mbar

Input - Max. (Gross) 6.0kW (20,472Btu/h) 6.1kW (20,813Btu/h)

Input - Min. (Gross) 2.3kW (7,848Btu/h) 3.8kW (12,966Btu/h)

Output - Max. 3.1kW (10,577Btu/h)

Output - Min 1.1kW (3,753Btu/h) 1.8kW (6,142Btu/h)

20.0 ± 1.0mbar (8.0 ± 0.4in

Inlet Test Pressure (Cold)

Gas Connection 8mm pipe 8mm pipe

Burner Injector Stereomatic Cat 82 - 069 Stereomatic Size 128

Pilot & Atmosphere Sensing

Device

Piezo Electric. Integral with

Ignition

Natural (G20) Propane (G31) *

w.g.)

Copreci Ref. O.D.S

21500/189

Gas Tap

0.4in w.g.)

Copreci Ref. O.D.S

180-02 injector

Gas Tap

Aeration See section 14.1 See section 14.1

Electrical Supply 230V ~ 50Hz AC 230V ~ 50 Hz AC

Fan motor rating 55W 55W

Fuse rating 3A 3A

* When converted using Kit 0595221.

removing the fire front castings / fire front.

3. GENERAL INSTALLATION REQUIREMENTS

3.1 The installation must be in accordance with these instructions.

members to work to recognised standards.

with the current edition of the IEE Wiring Regulations (BS7671).
In the United Kingdom the installation must also be in accordance with:
a) All the relevant parts of local regulations.
b) The current edition of the Building Regulations issued by the Department of the

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Electrical isolation of the unit should be by means of a switched 3A fuse spur that

should be readily accessible to the user, easily identifiable and sited within reach of the

As supplied, the appliance is suitable for homes constructed of brick, stone, etc.,

the appliance can be installed into walls up to a maximum thickness as shown below.

Installation to a timber framed building should be in accordance with the relevant

sections of Institute of Gas Engineers publication IGE/UP/7 “Gas installations in timber

conglomerate marble hearths are considered as non-combustible). The fire box must be

mounted on a non-combustible surface level with the hearth. The hearth must project at

least 300mm forward of the fire box front and be at least 625mm wide (see illustrations

INSTALLER GUIDE

Regulations issued by the Scottish Development Department.
c) All relevant codes of practice.
The relevant parts of the current editions of the following British Standards:-

BS 5440 Part 1
BS 5871 Part 2 & 3
BS 6891

In the republic of Ireland the installation must also conform with:
a) The current edition of IS 813 “Domestic gas installations”
b) All relevant national and local rules in force.
c) The current ETCI National Rules for Electrical Installation.

Where no specific instructions are given, reference should be made to the relevant
British Standard Code of Practice.

3.1.2

mains cable provided. It should only connect this appliance.

3.1.3 This fire is a fan flued appliance for installation on an outward facing wall of a
conventional home which does not have a purpose built flue or chimney.

3.1.4

If the fire box is in front of the finished wall surface: 600mm (23 5/8in) max.

These dimensions are from the finished internal wall surface (including any surround
material) to the external wall surface.

3.1.5

frame buildings”. Please note that advice should be sought before installing in a
timber frame building since the alterations required may nullify any NHBC cover
relating to the property. If in doubt, guidance should be requested from your local
authority planning or building department.

This appliance must be mounted with a non-combustible hearth (See figure 1) (N.B.

in “wall preparation” section). 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
casting to be aligned horizontally. Any excessive unevenness (uneven tiles, Cotswold

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appliance is to be fitted against a wall with combustible cladding or skirting board, such

suggest that the fascia is used as a template to mark the area for combustible cladding

The appliance can be fitted to a purpose made proprietary class “O” 150°C surround.

mm.

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. The minimum

INSTALLER GUIDE

stone, etc.) should be rectified.

Figure 1. Hearth and recess requirements

3.1.6 The appliance must not stand on combustible materials or carpets.
The appliance must not be fitted directly against a combustible wall. If the

materials must be removed from the area covered by the fascia of the appliance. We

removal.

The opening in the surround or wall recess for the fire box must be within the limits
shown in figure 1.

3.1.7. ‘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 at least 88

shelf height will have to be taken from the base of the fireplace opening.

3.1.8 The minimum height from the top surface of the hearth to the underside of any
shelf made from wood or other combustible materials is detailed below.

! For a shelf up to 150mm deep: Minimum height = 700mm.
! For a shelf deeper than 150mm: 700mm + 12.5mm for every 25mm depth over

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150mm (See Graph 1).

covered by the fire box top and side flanges to ensure a good seal. The minimum height

They may scorch or become discoloured when close to a heating appliance. Please bear

The appliance must not be installed in any room that contains a bath or shower or

An extractor fan may only be used in the same room as this appliance, or in any

performance of the appliance. Note the spillage test requirements detailed further on in

installed unless the fan is permanently disconnected, or provision is made to ensure that

requirements of this appliance. In GB reference should be made to BS 5871 Part 2 and

INSTALLER GUIDE

Graph 1.

3.1.9 The front face of the wall should be reasonably flat over the area that will be

from the top surface of the hearth to the underside of any shelf made from wood or
other combustible materials is as follows:­Note that soft wall coverings (e.g. embossed vinyl, etc.) are easily affected by heat.

this in mind when installing.

3.1.10

where steam is regularly present.

3.1.11

area from which ventilation for the appliance is taken, if it does not affect the safe

this manual. If the fan is likely to affect the appliance, the appliance must not be

the fan and the appliance cannot be used at the same time.
A fan-powered flue system tends to depressurise the room containing the appliance.

3.1.12 Normal adventitious ventilation is usually sufficient to satisfy the ventilation

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, however the spillage check (See further on in this

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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 manufacturers replacement

A fireguard complying with BS 8423 should be fitted for the protection of young

For access purposes a 50mm clearance is recommended from non-combustible surfaces.

A concealed gas supply connection can be made through the rear panel. Visible

front connection can be from the left or right side after an opening has been cut in the

INSTALLER GUIDE

guide) may indicate a need for further ventilation in order to ensure that there is
adequate air replacement. If necessary seek expert advice.

3.1.13 The appliance is fitted with an A.S.D (Atmosphere sensing device). If the

part should be fitted. The individual A.S.D components are not replaceable.

3.1.14

children, the elderly, or the infirm.

3.1.15 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 100mm.

3.1.16

appropriate side of the hearth casting.
Electrical connection is from the right side.

3.2 Flue Siting

3.2.1 The flue terminal should be located so that
the wind can blow freely across it at all times and
where any blockage due to leaves, snow, etc. is
unlikely. The minimum allowable distances from
the terminal are shown in figure 3.

Note: The distances are from the edge of the
vertical exit slots in the terminal not from the

edges of the rectangular box (See figure 2).

3.2.2 This appliance is supplied with a terminal

guard. In England and Wales, the Building
Regulations require that the terminal guard is fitted
if the flue terminal can come in contact with
people near the building or be subject to damage.
Even if the regulations do not demand it, we
recommend that the guard is fitted to prevent
damage or blockage of the flue system by leaves etc.

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Figure 2

INSTALLER GUIDE

fabric formed for the purpose of accommodating a built-in element such as a window frame

Dimension Terminal Position

A* Directly below an opening, air brick, opening window etc. 300mm

B* Above an opening, air brick, opening window etc. 300mm
C* Horizontally to an opening, air brick, opening window etc. 300mm

D Below gutters, soil pipes or drain pipes 75mm
E Below eaves 200mm
F Below balconies or car port roof 200mm
G From a vertical drain pipe or soil pipe 150mm

H** From an internal or external corner 200mm

I Above ground, roof or balcony level 300mm

J From a surface facing the terminal 600mm

K From a terminal facing the terminal 1200mm

From an opening in a car port (e.g. door, window) into

L

dwelling

M Vertically from a terminal on the same wall 1500mm

N Horizontally from a terminal on the same wall 300mm

Minimum

Distance

1200mm

*In addition, the terminal should not be nearer than 150mm to an opening in the building

or door frame (See figure 3b).
** The reference to external corners does not apply to building protrusions not exceeding

450mm, such as disused chimneys on external walls.

Figure 3

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INSTALLER GUIDE

Figure 3b.

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INSTALLER GUIDE

4. APPLIANCE DIMENSIONS

NOTE: ALL DIMENSIONS ARE APPROXIMATE AND SUBJECT TO

MANUFACTURING DEVIATION

Figure 4. Appliance dimensions (Shown with fascia that is close fitted to the outer
flanges of the hotbox. Dimensions ‘A’ and ‘B’ may differ depending upon the fascia
fitted)

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