Cast Tec Integra HE Installation And User Instructions Manual

Integra HE 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 3

Installation Requirements 4

Installation Procedure - Standard 22” x 16” 5

Installation Procedure - Decorative Cast 7

Commissioning 8

Technical Data 8

Replacement Parts 8

Trouble Shooting (GAS SAFE Engineer Only) 9

User Instructions 12

Cleaning and Maintenance 17

Fire Front Specifications 18

Modular Coal Layout Instructions 19

Guarantee 24

Trouble Shooting (User) 24

CONTENTS

2

This appliance has been designed, tested and manufactured to the British Standard BS 7977-1:2002 relating to
Radiant Convector Gas Appliances and must be 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
into 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. Never place combustible material directly in front of this appliance. Floor
covering such as carpet is acceptable but must be a minimum of 300mm from the incandescent flame.

NOTES FOR THE INSTALLER AND END USER

3

This fire is a very effective heating appliance and must be fitted against a wall of non-combustible material as
classified in BS 476-4:1970 (2007).

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 ten minutes of
lighting from cold. This can be verified by inserting a lit smoke match into the left and right hand ducts
immediately above the glass retaing strip. It should NOT be inserted into the central convector duct.
This operation should be carried out before fitting the trim and louvred panel (see ‘Spillage Test’ page 4).

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 12). 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

150mm (min)

50mm (min)

300mm (min)

Fig. 1

Fig. 2

195mm 512mm

612mm

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

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

a) Class 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 (unlined chimney 12 dm3 and lined 2 dm3). 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 fully open position. The chimney should also be swept prior to
installation.

b) Oversized Void - Where an oversized void is encountered it must be reduced in size by lining with bricks or
blocks or alternatively inserting a metal flue box. The nominal dimensions of the void should not exceed 650mm
wide x 475mm deep x 800mm high BS5871-2.

c) Class II - A double walled or insulated metal flue box built to the requirements of BS715 with an insulated flue
having a minimum diameter of 125mm (5”) and a minimum effective overall height of 3 metres (10’).

NOTE: If the flue box is to be used with an existing brick or stone chimney, a 125mm (5”) minimum diameter
flue liner conforming to BS715 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.

d) Pre-cast Flue conforming to BS 1289 Part 1 (It may be necessary to use a surround with a deeper rebate than
usual to accommodate a flush fit with certain starter blocks. Check the appliance dimensions against individual
applications.

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 5m

3

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 Test 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 ten minutes. Insert a lit smoke match into the left and right hand ducts immediately above the glass
retaing strip. It should NOT be inserted into the central duct. This operation should be carried out before fitting the
trim and louvred panel. 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. To 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

4

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. Remove the louvred panel by lifting
up and pulling forwards.

4. Slacken the five machine screws on
the top retaining strip (Fig. 3).

5. Unscrew the two securing screws
from the lower infill panel and remove the panel.
Tilt the glass forwards and slide out (Fig. 4).

6. 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.

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

5

Fig. 5

Burner tray

Blanking plate

Foam Sealing Strip

Magnetic Trim

2 x Securing Screws

Fig. 3

Fig. 4

5 x Machine Screws

Louvred Panel

INSTALLATION PROCEDURE FOR STANDARD 22” X 16” OPENING CONTINUED

6

Radiant box

Hearth

Eye Bolts

Centre Line

Drill Holes for 4 eye bolts

on 112mm centre lines

between max and min height.

65mm

min

Fix the radiant box into the opening, securing into position using the cable fixing kit (Fig. 8). Do not cut off the
loose ends as the full length is required should the radiant box need refitting at any time. Coil up and securely
store underneath the burner tray.

1. Position the burner tray into the box in order to determine the length of 8mm gas supply needed and cut to
length.

2. Before making the final connection, thoroughly purge the supply pipe to clear any foreign matter, i.e. masonry
dust etc, as this could lead to blockages in the control valve and/or pilot assemblies.

3. Fix the burner in place using the four screws and make the gas connection. Carry out a gas soundness test.

ALTERNATIVE FIXING METHOD

Where the drilling of the back panel is not practical, an alternative
fixing method may be employed using the optional cable fixing kit
provided. Drill four holes in the rear of the fireplace opening (Fig. 7).
Securely fix the four eye bolts provided using suitable rawl plugs.
Feed one cable through each of the top holes in the rear of the
fire box.

115mm

max

500mm

min

550mm

max

112mm

112mm

Tension Nut

Cable Clamping Screw

Fig. 7

Fig. 8

Cable

Rectangular
Cutout

Insert cable into rectangular cutout
and feed the end back through the
small hole above the cutout.

Fixing
Holes

Fixing
Holes

Fixing Holes

9. 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. The
gas supply should be concealed as much as possible. Both
blanking plates MUST be re-fitted or this could seriously
impair performance.

10. With 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.

11. 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.

Fig. 6

INSTALLATION PROCEDURE FOR DECORATIVE CAST SURROUND

7

1. Install the decorative cast surround into the fireplace opening and ensure it is fully sealed including the open
area above the fire (see Fig. 9).

2. Carefully lift the fire box out of the packaging taking care not to damage the ceramic components in the
separate carton.

3. Cut the foam sealing strip (in plastic bag supplied) to length and stick a continuous strip up one side, across
the top and down the other side of the rear of the radiant box. When the box is placed against the cast surround
the foam strip will form a seal around the boxes flange.

4. Lift the fire box on to the two studs at the top of the surround and
check that the flange of the radiant box fits flush against the sealing
face with no gaps present.

5. Locate the decorative frame on to the studs and secure with the
two nuts provided.

6. Insert the two screws into the lower holes in the decorative frame
and carefully tighten ensuring the fire box is securely clamped
between the frame and the surround.

Fig. 9

Decorative Cast
Surround

Securing
Studs

Securing Screws

Decorative Frame

ENSURE THIS AREA
IS SEALED

Foam Sealing Strip

1. Modular Coal Set - The ceramic coals supplied with this appliance can be replaced at service intervals
depending on their condition. If the coals do require replacement, the consumer can do so provided that the
Ceramic Component Layout Instructions (pages 19-20) are adhered to. Under no circumstances should
additional/extra coals be added. Only genuine Legend replacement parts should be used.
Order Ref: EVCS01

2. Oxygen Depletion Sensing Pilot - In the unlikely event of a pilot failure, the pilot assembly should only be
replaced by a Gas Safe Registered Engineer. The user must not carry out this work.
Order Ref: LEG62

3. TESC Valve - In the unlikely event of control valve failure, the assembly should only be replaced by a Gas
Safe Registered Engineer. The user must not carry out this work. Order Ref: ETH02

4. Glass Panel - Should the glass become cracked or broken, the fire should not be used under any
circumstance.
Order Ref: LEG59

5. Glass Rope Seal - The integrity of the glass rope seal should be checked on service and replaced if
necessary by a Gas Safe Registered Engineer.
Order Ref: LEG58

COMMISSIONING

8

Gas Type Natural Gas (G20) Cat I

2H

Gas Connection 8mm

Number of Injectors One

Injector size Stereomatic 1.70mm

Control Max Operating Temperature 80

o

c

Inlet Pressure Cold 20 mbar

Heat Input (Gross) 4.6 kW (Full) 3.0 kW (Reduced)

Weight 10.4 kg

NOx Level Class 5

REPLACEMENT PARTS

TECHNICAL DATA

1. Unscrew the inlet pressure test point sealing screw (Fig. 10) and fit a manometer.
Consult the user instructions (page 12). Ignite the appliance and turn to the high position.

2. Take a pressure reading and consult the technical data (below) to establish the
correct working pressure.

3. Once the pressure has been checked and verified, turn off the appliance.
Consult the ceramic component set up diagrams (pages 19-20) and fit the
ceramics as per the instructions.

4. Re-install glass panel. The glass should be positioned centrally to ensure the
decorative trim will fit over it.

5. Carry out a Spillage Test (page 4).

Inlet Pressure

Test Point

Fig. 10