Cast Tec Integra Fan Flue Installation And User Instructions Manual

Integra Fan Flue

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 3

Installation Requirements 4

Installation Procedure 6

Commissioning 10

Operating Sequence 11

Technical Data 11

Replacement Parts 11

Trouble Shooting (GAS SAFE Engineer Only) 12

Control Panel Wiring Diagram 13

Fault Finding Diagram 14

User Instructions 15

Cleaning and Maintenance 16

Fire Front Specifications 16

Coal Layout Instructions 17

Guarantee 19

Trouble Shooting (User) 19

CONTENTS

2

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

3

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.

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

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 14). 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.

Fireplace Opening

1

50mm (min)

50mm (min)

300mm (min)

Fig. 1

Fig. 2

1

45mm 512mm

608mm

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

1

. This appliance is a natural gas appliance only and has been designed for use with the following applications:

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
i

ncrements 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 TERMINAL POSITIONS

The minimum acceptable dimensions from the centre of the flue terminal grille to obstructions and ventilation
opens (Fig. 3).

Dimension Terminal Position Minimum

A

Directly below an opening, air brick, window etc.

300mm
B Directly above an opening, air brick, window etc. 300mm
C Horizontally to an opening, air brick, 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 or soil pipe 150mm
H From an internal or external corner or to a boundary

alongside the terminal 200mm

I

Above ground, roof or balcony level

300mm
J From a surface or boundary facing the terminal 600mm
K From another terminal facing the terminal 1200mm
L

From an opening in a car port 1200mm
M Vertically from another terminal on the same wall 1500mm
N

Horizontally from another terminal on the same wall

300mm

INSTALLATION REQUIREMENTS

4

Fig. 3

A

M

A

N

H

H

K

C

G

H

J

F

L

I

I

DE

B

VENTILATION

N

o special ventilation bricks or vents are required in the room containing the appliance, providing that normal

a

dventitious 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.

I

NSTALLATION INTO TIMBER FRAMED DWELLINGS

Where removal of any part of the inner timber leaf of the wall is involved, the structural integrity of the wall must be
maintained and the advice of your local Building Control Department should be sought. If the property is under any
N.H.B.C. cover, it is advised that their advice on this modification should also be sought.

Standard methods of installation may be adapted for use in timber framed buildings, providing extra care is taken to
prevent combustible materials from contact with hot surfaces.

The appliance must be installed in accordance with British Gas documents DM2 and DM3 or the Institute of Gas
Engineers published procedure IGE/UP/7.

Special attention must be paid to the location of the studwork frame of the inner leaf and the appliance positioned
accordingly. Wires and pipes that run within the inner timber leaf must also be located and taken into account when
positioning the appliance.

INSTALLATION USING EXTENDED FIRE SURROUND OR FALSE CHIMNEY BREAST

When using this method of installation the following amendments should be incorporated. 25mm clearance must be
allowed from the appliance firebox to any insulated combustibles. 75mm clearance must be allowed to any
unprotected combustibles.

50mm minimum thickness of insulation should be provided around the flue pipe and gather hood. Where the flue
pipe passes through the inner leaf, a hole 100mm larger than the flue should be cut to allow a 50mm air gap
around the entire flue circumference. The vapour barrier on the back of the inner leaf should be cut and carefully
fixed to prevent any ingress of damp into the plasterboard layer. A layer of insulation will need to be provided to
insulate the surface of the inner wall from the heat ef

fect of the flue. It may be advantageous to use a sheet of
Superlux board for this purpose. When setting the appliance into the inner wall find a suitable position between the
wall panel frames and carefully open up a hole to the dimensions given in the relevant section (section1), paying
careful attention to securing the damp proof membrane back into position. A Drip collar of galvanised or stainless
steel should be formed with the twisted joint on the underside of the flue to disperse drips. An air gap of 75mm
between all hot surfaces and the surrounding wall should be allowed, if protective insulation is used this may be
reduced to 25mm clearance.

The exposed cavity should be sealed off using Superlux or a similar non-combustible board. The board should be
fixed at an angle, lower at the back so as to direct any moisture coming down to the outside wall. This board should
be fixed with screws, Unibond, or a similar adhesive. It is important to fit this board or a cavity tray to protect the
property and the appliance from drips of water.

The sides of the opening where the cavity is exposed should be
packed with Rockwool or similar non-combustible material to a minimum depth of 50mm. The Rockwool packing
must extend from the base of the opening to the Superlux board.

NOTES ON ELECTRICAL INSTALLATION

1. External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this
is the current I.E.E. Wiring Regulations. In IE reference should be made to the current edition of ETCI rules.

2. The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance.

3. Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles.
The appliance must be positioned so that the switch is accessible.

4. If the appliance is to be fitted with a plug, the appliance must be positioned so that the plug is accessible.

5.

THE WIRES FEEDING THE FAN BOX MUST NOT BE ALLOWED TO TOUCH THE REAR OF THE FIRE BOX.

INSTALLATION REQUIREMENTS CONTINUED

5

INSTALLATION OF THE FIRE BOX

1. With the fire place fixed on a suitable outside wall, screed the recess to the level of the hearth. This ensures
a

ccurate fitting of the fire and flue spigot alignment with the fan unit.

2.

From Inside: Draw a vertical line centrally on the back wall of the fireplace opening. Measure 407mm up from
the hearth and place a mark on the line. With a suitable drill (approx 10mm) make a hole through to outside
ensuring the drill is kept level.

F

rom Outside: Draw a rectangle 215mm wide x 250mm high centrally above the centre of the drilled hole.

Note: To successfully install this system, the bottom edge of the wall plate must be at least 3” (75mm)
from the outside ground level.

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

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

5. 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 boxes flange.

6. Insulate the rear of the fire box with Rockwool or similar.

7. 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.

8. 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. 5).

INSTALLATION PROCEDURE FOR STANDARD 22” X 16” OPENING

6

Fig. 5

Blanking plate

Foam Sealing Strip

Magnetic Trim

Burner tray

Fig. 4

H

ole (10mm approx.)

Hole (10mm approx.)

Hearth Level

H

earth

O

utside Inside

2

15mm

250mm

407mm