Cast Tec Integra Installation And User Instructions Manual

Integra High Output Remote Control

Inset Live Fuel Effect Gas Fire

Installation and
Users Instructions

These instructions should be read by the
installer before installation and then should be
handed to the end user when the installation
is complete.

This is an official requirement and is the
responsibility of the fitter of this
appliance.

Having installed the appliance, the installer
should take the necessary steps to ensure
that the user fully understands how to operate
the appliance and is also made aware of the
fire’s basic cleaning and maintenance
requirements.

SECTION PAGE

Notes for the Installer and End User 4

Installation Requirements 5

Installation Procedure - Standard 22” x 16” 7

Installation Procedure - Decorative Cast 8

Commissioning 8

Technical Data 9

Replacement Parts 9

Trouble Shooting (GAS SAFE Engineer Only) 10

Remote Control Component Layout 11

Test Sequence 13

Fault Finding Table 14

User Instructions 15

Cleaning and Maintenance 16

Fire Front Specifications 17

Coal Layout Instructions 18

Guarantee 20

Trouble Shooting (User) 20

CONTENTS

3

THIS APPLIANCE IS INTENDED FOR DECORATIVE PURPOSES

T

his appliance has been designed, tested and manufactured to the European Standard EN509 relating to

D

ecorative Gas Appliances and

m

ustbe installed by a qualified GAS SAFE Registered Installer in accordance

with the Gas Safety (Installation and use) regulations 1994 and all other relevant standards.

This appliance must be connected in accordance with the National Regulations. The appliance must be sealed
i

nto a non-combustible fireplace (Fig. 2) whose only opening must be through a Class I (7” or 175mm diameter)

or Class II (5” or 125mm diameter) chimney/flue of at least three metres in height.

Before installation, ensure that the local conditions (identification of gas type and pressure) and the adjustment
of the appliance are compatible.

NOTES FOR THE INSTALLER AND END USER

4

An air vent is not normally required for this application because its input does not exceed 7kW. We recommend
that the chimney/flue is swept prior to installation of this appliance and that any flue restrictor or damper plate
should be removed or fixed in the open position. The chimney/flue must always generate a positive up draught to
ensure safe operation.

The installer must then establish that all the products of combustion are entering the flue within five minutes of
lighting from cold. This can be verified by traversing the canopy with a lighted smoke match (see ‘Spillage Test’
page 5).

An isolation valve must be fitted adjacent to the appliance. When closed, this will allow the complete burner and
control assembly to be disconnected for maintenance or repair in accordance with national regulations.

The gas supply should be provided by a semi rigid pipe with an 8mm diameter and should be no longer than 1.5
metres in length.

NOTE: When the gas supply pipe is passed through masonry or other brickwork always ensure that the end
of the pipe is covered to avoid any debris passing through into the appliance controls.
The appliance is fitted with an Oxygen Depletion Sensor (ODS) that monitors the room for products of
combustion. If products are detected, the ODS will automatically shut down the appliance. If this situation
arises, re-light the appliance, referring to the user instructions (page 15). If shut down re-occurs, a qualified
person must be called to thoroughly check the appliance. The spillage monitoring system (ODS pilot) must
not be put out of operation or be tampered with or adjusted by either the installer or the user

. If the unit is

found to be at fault it should be replaced with the manufacturers original replacement parts.

F

ireplace Opening

1

50mm (min)

50mm (min)

3

00mm (min)

Fig. 1

Fig. 2

195mm 512mm

608mm

This appliance must only be installed in Great Britain or Ireland.

1

. This fire is either a natural gas or LPG appliance and has been designed for use with the following

applications:

a

)

C

lass I-Conventional brick or stone chimney as used for a solid fuel fire with a cross sectional dimension of

225mm x 225mm (9” x 9”) or a lined flue with a minimum diameter of 175mm (7”), with the fireplace components
conforming to BS1251, or a builders opening a minimum of 560mm high and 406mm wide with a minimum depth
of 230mm to allow sufficient volume for debris collection. To obtain this depth it would not normally be necessary
to remove the chair brick. Any permanent flue restrictions or variable dampers are to be removed or locked in the
f

ully open position. The chimney should also be swept prior to installation.

b)

Class II - A double walled or insulated metal flue box built to the requirements of BS715 with an insulated flue

h

aving a minimum diameter of 125mm (5”) and a minimum effective overall height of 3 metres (10’).

N

ote: If the flue box is to be used with an existing brick or stone chimney a 125mm (5”) minimum

diameter flue liner conforming to BS 715 may be used.

2. A non-combustible hearth must be provided to comply with current building regulations. Care should be taken
to prevent any damage being caused to surrounding soft furnishings or decoration, e.g. many embossed vinyl
wall coverings may become discoloured if placed too close to the appliance.

3. A suitable proprietary fire surround with 100

0

c rating may be used with a minimum clearance from hearth to

underside of shelf of 830mm, providing that the depth of shelf is 150mm or less.

4. Where the shelf depth is greater than 150mm, the minimum height clearance should be increased by 25mm
increments for each additional 12.5mm of shelf depth.

5. Minimum width between vertical sides of combustible surround should not be less than 800mm provided the
appliance is central to the surround and the surround legs do not exceed a 150mm profile.

6. If the 150mm profile is exceeded, the width of the surround (and the back panel) should be increased by
25mm for each additional 12.5mm of profile depth.

FLUE FLOW TEST

A flue flow test (smoke test) is carried out to check the effectiveness of the flue and to ensure that there is no
leakage into another part of the premises (including any loft), or as appropriate other adjoining premises (this is
particularly important where a number of chimneys combine into a multiple stack).
The flue flow test should be carried out using a suitable smoke pellet which the pellet manufacturer claims to
generate 5 m3 of smoke in 30 seconds burn time.
These gas fires should have the flue flow test carried out with the appliance in position but not connected to the
gas supply so that the smoke test can be carried out with representative flue flow conditions.
A warm flue will be more effective than a cold flue. If the flue is reluctant to draw, which can be initially assessed
by lighting a smoke match at the intended position of the appliance flue connection, introduce some heat into the
flue for a minimum of 10 minutes using a blow torch or other means.
Other factors, such as weather conditions and a combination of materials used to construct the flue can all
influence the flue draught. The pre-heating process may require as much as half an hour before the flue behaves
satisfactory as a blow torch does not represent the volume of heat consistent with the normal appliance
operation.

A

Flue Flow

T

est should be checked as follows:

1. Carry out those visual checks as indicated previously, and continue only if satisfactory.

2. Establish that an adequate air supply is available for the combustion of the appliance

3. Close all doors and windows in the room that the appliance is to be installed.

4. Light a smoke pellet at the intended position for the appliance. Place the inset fire case into position.

5. The test is satisfactory if

- there is no significant escape of smoke from the appliance position.

- there is no seepage of smoke over the length of the flue.

- smoke is discharged only from the correct terminal.

VENTILATION

No special ventilation bricks or vents are required in the room containing the appliance, providing that normal
adventitious room ventilation exists. The installer must determine this by carrying out a spillage test.

SPILLAGE TEST

To check for satisfactory clearance of products of combustion, close all doors and windows and leave the fire
burning for five minutes. Insert a lit smoke match on a vertical plane 50mm down, 50mm inside the canopy
opening.

All the smoke must be drawn into the flue. If spillage occurs, allow a further ten minutes and repeat the
test. Should spillage still occur turn the appliance off and seek expert advice.
T

o continue the test: If an extractor fan is situated in the room the test should be repeated with the fan running. If
there is a connecting room with an extractor fan the test should be repeated with all the doors to that room open
and the extractor fan running.

INSTALLATION REQUIREMENTS

5

1. Carefully lift the appliance out of the packaging taking care not to damage the ceramic components in the
separate carton.

2. Remove the magnetic trim and store to one side to prevent any damage.

3. Cut the foam sealing strip (in plastic bag supplied) to length and stick a continuous strip down the two sides
and across the top of the radiant box. When the box is placed against a flat surface the foam strip will form a
seal around the box’s flange.

4. Carefully lift the appliance into position in the fireplace opening and check that the flange of the radiant box
fits flush against the sealing face with no gaps present.

5. Remove the four screws that secure the burner tray to the box, two on the front leg and two at the rear of the
tray. Remove the burner tray and place to one side (Fig. 3).

6. When the burner tray has been removed, decide which side of the appliance the gas supply will be entering
the radiant box and remove the relevant blanking plate (left or right hand side). The gas supply should be
concealed as much as possible.

7. W

ith the radiant box placed in the opening, mark out four of the eight fixing holes. Remove the box and

carefully drill and fit rawl plugs.

8. Pass the 8mm gas connection through the back of the
box and secure the box into place using four screws
(straight shank screws are recommended for marble).
Check that the outer flange of the appliance is completely
sealed against the back panel.

INSTALLATION PROCEDURE FOR STANDARD 22” X 16” OPENING

6

Fig. 3

Fig. 4

Burner tray

B

lanking plate

Foam Sealing Strip

Magnetic Trim

Fixing
Holes

Fixing
Holes

Fixing Holes