Charnwood DX45iB, DX50iB Operating And Installation Instructions

Operating

and

Installation Instructions

Charnwood

DX45iB & DX50iB

Multifuel Roomheater

With Boiler

Bishops Way, Newport, Isle Of Wight, PO3O 5WS, U.K.

Tel: [phone] Fax: [phone]

E-Mail: [e-mail]

CHARNWOOD DX45iB & DX50iB

Operating

and

Installation Instructions

Contents

Operating Instructions

General Points.............................................. 2

Fuels ............................................................ 2

Door Operation ............................................ 2

Multifuel Grate ............................................ 2

Lighting....................................................... 3

Controlling The Fire.................................... 3

Running The Fire With The Doors Open..... 3

System Controls........................................... 3

Ash Clearance..............................................3

Riddling....................................................... 3

Refuelling .................................................... 4

Overnight Burning ....................................... 4

Throat Plate & Flueway Cleaning................ 4

Special Points When Burning Coal.............. 4

Maintenance................................................. 5

Chimney Sweeping ...................................... 5

Trouble Shooting..........................................5

Installation Instructions

Health & Safety Precautions......................... 7

Performance................................................. 7

Chimney ...................................................... 7

Hearth.......................................................... 8

Preparation Of Fireplace .............................. 8

Central Heating System................................ 8

System Controls........................................... 9

Fitting The Fire............................................ 9

Flue Connection & Infilling.........................9

Thermostat................................................... 10

Assembly...................................................... 10

Pre-Lighting Check......................................10

Commissioning............................................ 10

Overall Dimensions...................................... 11

Exploded Parts Drawing .............................. 12

Bishops Way, Newport, Isle Of Wight, PO3O 5WS, U.K.

Tel: [phone] Fax: [phone]

E-Mail: [e-mail]

GENERAL POINTS

Before lighting the fire check with the
installer that the work and checks
described in the installation
instructions have been carried out
correctly and that the chimney has
been swept, is sound, and free from
any obstructions.

WARNING There must not be an
extractor fan fitted in the same room
as this appliance as this can cause the
appliance to emit smoke and fumes
into the room.

If the appliance is fitted in place of an
open fire then the chimney should be
swept one month after installation to
clear any soot falls which may have
occurred due to the difference in
combustion between the appliance and
the open fire.

When using the fire in situations
where children or infirm people are
present please use a fire guard to
prevent accidents. The fire guard
should be manufactured in accordance
with BS 6539.

This appliance has been designed to
conform with BS.3378. It has obtained
the approval of HETAS Ltd. (formerly
DSFAAS Ltd.) for burning the fuels
listed under the heading ‘‘Smokeless
Fuels’’.

FUELS

The following fuels may be burnt on
this fire. Please pay careful attention
to the special points made with each
type of fuel as they will help you to
get the best from your fire. It must be
remembered that only smokeless fuels
may be burnt in smoke control areas
on this fire. If you are not sure
whether you are in a smoke control
area, then please check with your
Local Authority.

Smokeless Fuels

HETAS Ltd. approval only covers the
use of the following smokeless fuels
on this appliance:

Ancit,
Anthracite Stove Nuts,
Centurion,

Cosycoke
Extracite,
Homefire,
Maxibrite,
Phurnacite,
Sunbrite Doubles,
Welsh Dry Steam Coal (Large Nuts).

Approval does not cover the use of
other fuels either alone or mixed with
the above fuels, nor does it cover
instructions for the use of other fuels.

The above smokeless fuels are all
suitable for use in smoke control
areas.

Coal

Housecoal doubles, trebles or cobbles
may all be burnt. Do not use singles,
small nuts, or coal dust

It is important that large size coal is
used (ie. larger than 2’’ or 50 mm in
size). The coal should be dry.

When burning bituminous coal a little
extra care is needed. Please take note
of the section ‘‘Special Points For
Burning Coal’’.

Wood

Only dry well seasoned wood should
be burnt on this appliance as burning
wet unseasoned wood will give rise to
heavy tar deposits. For the same
reason hard wood is better than soft
wood. Burning wet unseasoned wood
will also result in considerably
reduced outputs. The wood should be
cut and split and then left to season in
a well ventilated dry place for at least
one year but preferably two years
before use.

Peat

Ensure that the peat is well dried
before use. Burning wet peat will give
rise to heavy tar deposits and reduced
outputs.

PETROLEUM COKE IS NOT

SUITABLE FOR USE ON THIS

APPLIANCE, ITS USE WILL

INVALIDATE THE

GUARANTEE

At first you may find it helpful to try

several fuels to find the most suitable.
If you are unable to obtain the fuel
you want ask your supplier, an
approved fuel distributor, or the Solid
Fuel Association (tel [phone],)
to suggest an alternative.

DOOR OPERATION

Use the spanner type tool to open and
close the doors. Turn the knob on the
right hand door anti-clockwise to open
and clockwise to close. When closing
the doors do not push on the enamel
with the tool as this can chip the
enamel, instead push the doors on the
door knobs.

There is a safety device fitted to the
fire which prevents the main doors
being closed when the ashpit door is
open. This is to prevent accidental
over-firing.

The sequence for opening and closing
the doors is as follows:

Open the main doors Open the ashpit
door Close the ashpit door Close the
main doors

MULTIFUEL GRATE

Your Charnwood is fitted with a
multifuel grate which enables solid
fuel, wood and peat to be burned
equally effectively.

The grate has two positions. One for
solid fuel, the other for wood and
peat. When in the solid fuel position
ash can fall through the grate and into
the ashpan. When in the wood
position ash is able to build up on the
grate as is necessary for effective wood
or peat burning.

Movement of the grate from one
position to the other is effected using
the tool supplied. The grate is put into
the wood position by moving the tool
in the direction of the arrow ‘W’
(marked on the handle of the tool)
until the tool is vertical. The grate is
put into the solid fuel position by
moving the tool in the direction of the
arrow ‘C’ until the tool is horizontal.

If a mixture of wood and solid fuel, or
peat and solid fuel, is to be burnt then
keep the grate in the solid fuel

OPERATING INSTRUCTIONS FOR THE

CHARNWOOD DX45iB & DX50iB

Page 2

DX50iB 3/99

position.

LIGHTING

Set the grate into either the wood
position or the solid fuel position as
required. Place some paper and dry
kindling wood or fire lighters on the
grate and cover with a small amount
of fuel. Turn the thermostat control
knob to the maximum setting and
light the paper or fire lighters. Close
the doors and allow the fire to burn
until the fuel is well ignited then load
with more fuel and adjust the
thermostat to the required level.

On initial lighting, the fire may smoke
and give off an odour as the silicon
paint with which the firebox is
painted reacts to the heat. This is
normal and will cease after a short
time. In the meantime the room
should be kept well ventilated.

Before relighting the fire, riddle,
remove any clinker from the firebed
and empty the ashpan.

CONTROLLING THE

FIRE

The rate of burning and hence the
output is controlled by the control

knob on the left hand side of the
appliance, shown in Fig. 1. This is
linked to a thermostat which controls
the boiler temperature. The number at
the top of the knob is the number at
which it is set. Some experimentation
may be necessary to obtain the desired
heat output.

There is also a manual secondary air
control which is located at the bottom
of the right hand side panel, see Fig.

2. When the arm is pointing to the
right it is closed, when pointing
backwards it is open. This control
should be in the closed position when
burning most smokeless fuels and in
the open position when burning coal,
wood, peat, anthracite, or homefire.

RUNNING THE FIRE

WITH THE DOORS

OPEN

The fire may be run with the doors
open. This will result in a reduction in
efficiency and hence heat output,
particularly to the boiler. The more
reactive fuels, like coal, homefire,
wood, and peat, will burn better when
the doors are open than fuels like
phurnacite, sunbrite and ancit.

For safety reasons use a spark guard
and do not leave the fire unattended
with the doors open.

SYSTEM CONTROLS

The heating system controls may
consist of time switches, room
thermostats, outdoor temperature
thermostats and thermostatic radiator
valves in virtually any combination.
These will work in conjunction with
the thermostat control on the
appliance. The thermostat on the
appliance will simply control the
temperature of the water coming from
the boiler and hence the temperature
of the radiators and domestic hot
water. The automatic controls (other
than thermostatic radiator valves) will
switch the pump (and hence the
radiators) on and off. Your installer
will be able to explain the controls
fitted to your system and how to
operate them.

ASH CLEARANCE

The ashpan should be emptied
regularly before it becomes too full.
The most convenient time to remove

the ash is just before riddling the fire
since the ash will then be at it’s
coolest. Use the tool provided to
remove the ashpan.

Never allow the ash to accumulate in
the ashpan so that it comes in contact
with the underside of the grate as this
will seriously damage the grate bars.
Ensure that the air inlet damper is not
prevented from closing by spilled fuel
or ash.

Care should be taken to ensure that
ash is cool before emptying it into
plastic liners or bins.

Always close the ashpit door tightly
after replacing the ashpan.

To make ash removal easier there is a

special Charnwood ash carrier
available.

This may be purchased
from your supplier or, in case of
difficulty, from ourselves.

RIDDLING

When burning solid fuels riddling
twice a day is usually sufficient. When
burning wood or peat, ash should be
allowed to build up and generally
riddling every other day will be
sufficient.

1

2

3

4

5

0

Fig. 1. Thermostat Control

Air Inlet Damper

Control
Knob

Fig. 2. Secondary Air Control

Open

Closed

Control Arm

Page 3

DX50iB 3/99

The fire should be riddled with all
doors shut. Place the tool on the knob
and rotate between the horizontal and
the 45 degree position several times as
shown in Fig. 3.

When burning wood or peat do not
riddle all the ash into the ashpan,
keep a layer about 12 mm (1/2 inch)
thick on the grate.

Caution: when riddling the grate
using solid fuel do not go beyond the
45 degree position as this can cause
the grate to jam.

If jamming does occur then the fire
should be allowed to burn for
approximately half an hour before
riddling the grate again as described
above.

Too much riddling can result in
emptying unburnt fuel into the ashpan
and should therefore be avoided.
Clinker should regularly be removed
from the firebed.

After riddling, the grate should be put
back into the solid fuel or wood

position as required (the tool should
be horizontal for solid fuel or vertical
for wood or peat).

REFUELLING

Keep the firebox well filled (the fuel
may be sloped up from the front
firebars), but do not allow fuel to spill
over the top of the front fire bars.
Take care, especially when burning
wood, that fuel does not project over
the front fire bars or damage to the
glass may be caused when the doors
are closed.

OVERNIGHT

BURNING

Empty the ashpan, if necessary, and
then riddle the fire if you are burning
solid fuel. If the fire is very low then
it may be necessary to add a little fuel
and turn the thermostat control up to
maximum for a brief period until the
fire is burning brightly before filling
with fuel. When burning wood use
large logs overnight as they will burn
more slowly than small ones.

If the central heating pump is off
overnight then the thermostat may be
left at the same setting for both day
and night operation. If the central
heating pump is on overnight then set
the thermostat control to give the
required level of heating.

Some experimentation may be
necessary to find the setting most
suitable for the particular fuel used
and the draw on the chimney.

For overnight burning the fire doors
must be closed.

To revive the fire, empty the ashpan if
necessary, riddle, (when burning solid
fuel), and turn the thermostat control
knob to maximum. When the fire is
burning well load on more fuel as
necessary and turn the control knob to
the desired setting.

When burning wood do not riddle but
simply turn the air control to
maximum until the fire picks up and
then set the air control at the desired
setting and refuel as necessary.

THROAT PLATE AND

FLUEWAY CLEANING

It is important that the throat plate
and all the appliance flueways are

kept clean. When burning smokeless
fuels they should be cleaned monthly.
When burning other fuels they should
be cleaned at least once a week, and
more frequently if necessary.

The throat plate and flueways may be
cleaned with a low fire still burning.
Lower the throat plate using the throat
plate tool. To do this engage the end
of the tool in the throat plate as shown
in Fig.4., pull the plate forward and
then lower it. Use the scraper tool to
push any sooty deposits up the plate
until they fall off the back and into the
fire. While the throat plate is in the
lowered position also scrape any soot
deposits from the sides and top of the
firebox.

Ensure that soot deposits are
not allowed to build up on the side
boiler faces because if the throat
plate becomes tight between the
faces this can cause it to fail
prematurely.

Return the throat plate to its correct
position - raise the front of the plate,
push it back and then lower it onto the
retaining lugs. The upper set of lugs
are for use when burning smokeless
fuels and the lower set of lugs are for
use when burning coal, wood or peat
(see Fig. 4.).

More soot will be deposited on the
throat plate and in the flueways if the
appliance is run at low levels for long
periods. If this is the case then more
frequent cleaning will be necessary.

SPECIAL POINTS

WHEN BURNING

COAL

When burning housecoal keep the
throat plate in the lower position and
the secondary air control open all the
time (refer to Fig 4. and Fig 2.).

When loading the appliance take care
not to smother the fire, instead fill the
firebox in two stages waiting between
each stage for the flames to appear
above the fire.

After a period of slumbering always
turn the air control up to maximum
and wait until flames appear above the
fuel bed before opening the doors.

Burning coal will produce more soot
deposits than other fuels, especially if
the fire is run at low levels for long
periods. It is therefore vital to clean
the throat plate regularly, daily

C

W

Fig. 3. Grate Operation

For Wood

Do Not Go Beyond
45° Position
When Riddling

Riddle Between
Horizontal &
45° Positions

Tool To Be
Horizontal
For Solid Fuel

Vertical

Tool to be

Page 4

DX50iB 3/99

cleaning is recommended.

MAINTENANCE

The appliance is finished in vitreous
enamel. To clean the surfaces simply
wipe over with a dry cloth. Abrasive
pads and scouring cleaners must not
be used as these will damage the
finish. Care should be taken not to
knock the enamel with hard objects as
it will chip.

Cleaning the Glass

The glass in the doors is a special
ceramic glass which is able to
withstand high temperatures. Before
cleaning the glass open the doors and
allow them to cool. Clean the glass
using a damp cloth and then wiping
over with a dry cloth. Any stubborn
deposits on the glass may be removed
with a proprietary stove glass cleaner
or ceramic hob cleaner. Some deposits
on the glass may be burnt off simply
by running the fire at a fast rate for a
few minutes. Do not use abrasive
cleaners or pads as these can scratch
the surface which will weaken the
glass and cause premature failure.

When not in use

If the fire is going to be out of use for
a long period, (for instance in the
summer,) then to prevent condensa­tion, and hence corrosion, the
thermostat should be left at the
maximum setting and the main doors

left ajar. It is also advisable to sweep
the chimney and clean out the fire.
Spraying the inside of the doors and
firebox with a light oil, such as
WD40, will also help to keep all
internal parts working well.

After long periods where the fire has
been out of use, the chimney and
appliance flueways should be cleaned
before lighting.

Door Seals

For the fire to operate correctly it is
important that the door seals are in
good condition. Check that they do
not become worn or frayed and
replace them when necessary.

Servicing

It is recommended that the fire is
serviced once a year to keep it in first
class working order. After cleaning
out the firebox thoroughly, check that
all internal parts are in good working
order, replacing any parts that are
beginning to show signs of wear.
Check that the doors seals are in good
condition and that the doors seal
correctly. Check the operation of the
thermostat, both when cold and hot. A
servicing guide, TIS 48. is available
on request.

CHIMNEY SWEEPING

The chimney should be swept at least
twice a year. In most installations it
will be possible to sweep the chimney
through the appliance.

First remove the front firebars and the
throat plate. Then sweep the chimney
ensuring that soot is removed from all
horizontal surfaces after sweeping.

In situations where it is not possible to
sweep through the appliance the
installer will have provided alternative
means, such as a soot door. After
sweeping the chimney the appliance
flue outlet and the flue pipe
connecting the appliance to the
chimney must be cleaned with a flue
brush.

After clearing any soot from within
the appliance, replace the throat plate
and the front firebars.

Different types of sweep’s brushes are
available to suit different flueways.
For standard brick chimneys a wire
centre sweep’s brush fitted with a
guide wheel is recommended. For
prefabricated insulated chimneys the

manufacturers instructions with regard
to sweeping should be consulted.

TROUBLE SHOOTING

Fire Will Not Burn.

Check that:
a) the air inlet is not obstructed in any
way,
b) that chimneys and flueways are
clear,
c) that a suitable fuel is being used,
d) that there is an adequate air supply
into the room,
e) that an extractor fan is not fitted in
the same room as the appliance.

Fire Blazing Out Of Control.

Check that:
a) the doors are tightly closed,
b) the thermostat knob is turned down
to the minimum setting,
c) the air inlet damper is closed (at
the bottom left of the appliance), and
that it is not prevented from closing
completely by a piece of ash,
d) a suitable fuel is being used,
e) the door seals are in good
condition.

Over-Firing

If the fire is over-fired it will cause
premature failure of the internal fire
parts. Overfiring is occurring when
any internal parts of the fire begin to
glow red. To prevent over-firing
ensure that:
a) the ashpit door is kept tightly
closed at all times,
b) the door seals are kept in good
condition, and that the doors are
sealing correctly,
c) the thermostat on the fire is
working correctly,
d) a suitable fuel is being used,
e) the fire is not fitted onto a heating
system which is too large.

Fume Emission.

Warning Note:
Properly installed and operated this
appliance will not emit fumes.
Occasional fume from de-ashing and
re-fuelling may occur. Persistent
fume emission is potentially
dangerous and must not be
tolerated. If fume emission does
persist then the following immediate
actions should be taken:

A) Open doors and windows to

Fig. 4. Throat Plate

Positions & Operation

Pull Forward

Swing Down

Throat Plate

Lowering Tool

in the Smokeless fuel position

The Throat Plate is shown

Throat Plate

Upper Bracket
smokeless fuels)

(for burning

Lower Bracket
(for burning
coal, wood & peat)

Page 5

DX50iB 3/99

ventilate the room.
B) Let the fire out and safely
dispose of fuel from the appliance.
C) Check for flue or chimney
blockage, and clean if required.
D) Do not attempt to relight fire
until cause of fume has been
identified, if necessary seek
professional advice.

The most common cause of fume
emission is flueway or chimney
blockage. For your own safety these
must be kept clean.

Freezing

Do not light the fire if there is any
possibility that any parts of the system
may be frozen.

Chimney Fires.

If the chimney is thoroughly and
regularly swept, chimney fires should
not occur. However, if a chimney fire
does occur turn the control knob to the
minimum setting, and tightly close the
doors of the appliance. This should
cause the chimney fire to go out in
which case the control should be kept
at the minimum setting until the fire
in the appliance has gone out. The
chimney and flueways should then be
cleaned. If the chimney fire does not
go out when the above action is taken
then the fire brigade should be called
immediately.

After a chimney fire the chimney
should be carefully examined for any
damage. Expert advice should be
sought if necessary.

Page 6

DX50iB 3/99

HEALTH AND SAFETY

PRECAUTIONS

Please take care when installing the
appliance that the requirements of the
Health and Safety at Work Act 1974
are met.

Some types of fire cement are caustic
and should not be allowed to come
into contact with the skin. In case of
contact wash with plenty of water.

If there is a possibility of disturbing
any asbestos in the course of
installation then please use
appropriate protective equipment.

There must not be an extractor fan
fitted in the same room as the fire as
this can cause the appliance to emit
fumes into the room.

There must be an adequate air supply
into the room in which the appliance
is installed totalling at least 100
square cm. (16 square inches) to
provide combustion air. This is
particularly necessary if the room is
double glazed.

In addition to these instructions the
requirements of BS:8303 and BS:6461
Pt 1&2; 1984 must be fulfilled. Local

Authority Byelaws and Building
Regulations regarding the installation
of Solid Fuel burning appliances, flues
and chimneys must also be observed.

PERFORMANCE

The rated output for the DX45iB is

10.1 kW (34500 btu/h) to water and

3.1 kW (10600 btu/h) to the room.
The rated output for the DX50iB is

12.0 kW (41000 btu/h) to water and

2.2 kW (7500 btu/h) to the room.
These are the outputs obtained during

testing in accordance with BS 3378
burning the standard test fuel with the
doors closed over a 4 hourly
re-fuelling interval. The heat output to
the room is directly proportional to
the heat output to water as shown in
Fig. 5. This means that if the water
heating load is less than the rated
output then the room heating will be
reduced by the same proportion. This
must be borne in mind when
calculating the heating requirements.

CHIMNEY

In order for the appliance to perform
satisfactorily the chimney height must
not be less than 4 metres measured
vertically from the outlet of the
appliance to the top of the chimney.
The chimney should preferably be 175
mm (7 inches) or 200mm (8 inches)
internal diameter or square with sides
of 175mm or 200mm internally and

MUST NOT BE LESS THAN
150mm (6 INCHES) INTERNAL
DIAMETER OR 150 x 150mm
INTERNAL SQUARE.

If an existing chimney is to be used it
must be swept and checked, it must be
in good condition, free from cracks
and blockages, and should not have an
excessive cross sectional area (eg.
greater than 250mm x 250mm). If you
find that the chimney is in poor
condition then expert advice should be
sought regarding the necessity of
having the chimney lined. If it is
found necessary to line the chimney
then a lining suitable for Solid Fuel
must be used.

If there is no existing chimney then a
prefabricated block chimney or a twin
walled insulated stainless steel flue to
BS:4543 can be used either internally
or externally. These chimneys must be
fitted in accordance with the
manufacturers instructions and
Building Regulations.

Single wall flue pipe is suitable for
connecting the appliance to the
chimney but is not suitable for using
for the complete chimney.

If it is found that there is excessive
draw in the chimney then a draught
stabilizer should be fitted.

INSTALLATION INSTRUCTIONS FOR THE

CHARNWOOD DX45iB & DX50iB

Fig. 5. Performance Chart

0

2.0

4.0

6.0

8.0

10.0

12.0

1.0 2.0 3.0

Boiler

Output

(kW)

Space Output (kW)

DX50iB

DX45iB

Fig. 7. Limiting Dimensions Of

Surround And Opening

Fig. 6. Limiting Dimensions

Of Hearth

Minimum

400 mm

265 mm

This Dimension Is The
Minimum Level Area
Required To Enable The
Ashpit Door To Be
Opened.
For Overall Sizes Of
Hearth See The
Section Titled "Hearth".

A

B

Dim. A:

Dim. B:
Max. 575mm (22 2/3")
Min. 555mm (21 3/4")

Max. 470mm (18 1/2")
Min. 405mm (16")

The shaded area on the face of
the surround is the minimum flat

area required.

750 mm

660 mm

Page 7

DX50iB 3/99

HEARTH

The appliance must be installed on a
fireproof hearth and must be situated
at least 300 mm (12 inches) from any
combustible material. The positioning
of the appliance and the size of the
hearth are governed by building
regulations for Class 1 appliances.
These building regulations state that
the hearth must extend in front of the
appliance by at least 300 mm (12
inches) and to the sides by at least
150 mm (6 inches). If in doubt as to
the positioning of the appliance expert
advice should be sought either from
the supplier or the local building
inspector.

PREPARATION OF

FIREPLACE

Before fitting the appliance into an
existing fireplace remove the fireback
and any loose in-fill material.

The hearth, surround and opening for
the appliance must conform with Figs.
6 and 7. The flat area around the
opening must be a minimum of 750
mm wide and 660 mm high. Ensure
that the hearth and the base in the
opening are flat, level, and at right
angles to the surround.

Make two holes in the chimney breast,
one in the front to give access for
infilling and fixing the flue pipe, and
one in the side to give access for the
pipework.

CENTRAL HEATING

SYSTEM

The central heating system must
comply with BS:5449 part 1.

If the system is to be a combined
heating and domestic hot water system
then a double feed indirect hot water
storage cylinder to BS:1566 part 1
should be used. In order to prevent the
build up of scale and corrosion a
suitable inhibitor should be used. The
system must be correctly vented as
shown in Figs. 8 and 9. The height
differential between the header tank
and the appliance must not exceed

15.2 metres (50 feet).
If all four boiler tappings are used

then, if possible, diagonal pairs should
be connected for domestic hot water
and central heating. Where a common

Central Heating Flow

Central Heating Return

Drain Cock at Lowest Point

Drain Cock

Gravity Return 28mm

Gravity Flow 28mm

Indirect Hot Water Cylinder

Cold Water Tank

Overflow

Feed and Expansion Tank

22mm Open Vents

Gravity Radiator

Circulating Pump

Central Heating Return

Drain Cock at Lowest Point

Drain Cock

Gravity Return 28mm

Gravity Flow 28mm

Indirect Hot Water Cylinder

Domestic Hot Water Draw Off

Cold Water Tank

Overflow

Overflow

Feed and Expansion Tank

22mm Open Vents

Gravity Radiator

Circulating Pump

Injector Tee

Minimum Return Thermostat

Gravity Return

(28mm Pipe)

Central Heating Return

Common Return to Boiler

Central Heating Flow

Minimum Return
Thermostat

(28mm Pipe)

Overflow

Domestic Hot Water Draw Off

Fig. 8. Typical Central Heating & Hot Water System

Using 4 Boiler Tappings

Fig. 9. Typical Central Heating & Hot Water System

Using 3 Tappings

Fig. 10. Injector Tee.

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DX50iB 3/99

return is used an injector tee must be
incorporated into the system as shown
in Fig. 10. This will ensure that a
good domestic hot water supply is
maintained when the central heating
pump is operating.

The system must incorporate a gravity
circuit which will normally heat the
domestic hot water and an unvalved
radiator with an output of at least 1
kW. When the appliance is not
connected to a domestic hot water
system the unvalved radiator(s) on the
gravity circuit must have an output of
at least 1.25 kW. This is to prevent
boiling in case of pump failure. All
pipework in the primary circuit must
be 28 mm diameter and the gravity
flow pipe must rise continuously from
the boiler to the open vent. Two
typical systems are shown in Figures

8. and 9.
If the appliance is used to heat a small

central heating system then the heat
output to the room from the fire will
be reduced. Fig. 5. shows the ratio of
space heating to water heating which
can be expected.

Fitting a radiator in the same room as
the appliance is recommended as it
will allow greater flexibility in the
way that the system is operated as well
as ensuring that there is sufficient
heat.

SYSTEM CONTROLS

The circulating pump may be
controlled by means of time switches,
room thermostats or outdoor
thermostats. Radiators may be either
manually or thermostatically
controlled. These controls will all
work in conjunction with the
thermostat on the appliance and the
minimum return thermostat.

We recommend fitting a minimum
return thermostat to the gravity return
and wiring it into the mains supply to
the pump so that if the gravity return
temperature drops below 45° C then
the pump will cut out. This will help
to prevent condensation forming on
the boiler faces and will thereby
increase the life of the boiler. Use of a
minimum return thermostat also
ensures that priority is given to the
domestic hot water. These thermostats
are available from ourselves if you are
unable to obtain them locally.

FITTING THE FIRE

In some cases it may be necessary to
place the connecting flue pipe in the
chimney before fitting the appliance
into the fireplace.

Apply fire cement to the rear face of
the sealing flange on the appliance.
Fit it into the opening ensuring that it
is central and that a good seal is made
between the sealing flange and the
face of the surround.

The fire should be screwed to the
hearth through the holes at the base of
the sealing flange.

Remove any excess fire cement from
around the sealing flange.

Connect the heating system to the
boiler ensuring that the primary flow
pipe rises from the fire. Fill the system
with water and check for leaks.

FLUE CONNECTION

AND INFILLING

Make the flue connection with a short
length of

150mm (6’’) internal

diameter

flue pipe (cast iron to BS41,

1.0 mm thick stainless steel, or 5.0mm
thick mild steel)

.

The end of the flue pipe must line up
with the centre-line of the chimney,
and must also extend to the point
where the chimney narrows to its final

size. Any large voids must be filled
and flaunched to the flue pipe to
ensure that all soot deposits can be
cleared when the chimney is swept. If
necessary a flue offset is available.
The offset may be used directly with
stainless steel flue pipe or may be
used with cast iron flue pipe in
conjunction with the cast iron adaptor.
If the flue pipe has to be set at an
angle then cut the ends so that it sits
correctly.

Ensure that the flue pipe is not
obstructed or restricted in any way
and that all joints are well sealed.

Before infilling cover the front of the
appliance to protect it. Ensure that the
flue pipe is central and then fill the
space between the body of the
appliance and the structural brickwork
with vermiculite (eg. micafil or
similar) concrete. Ensure that there
are no air pockets. The recommended
mix is six volumes of vermiculite
granules to one volume of Portland
cement thoroughly mixed together.
Enough water should be added so that
no more than one or two drops of
water are released when a handful of
the mixture is squeezed.

After filling with vermiculite flaunch
the top of the flue connector pipe to
the chimney with lime mortar.

Make good the holes in the front and
side of the chimney breast making
sure that they are completely airtight.
A typical installation is shown in

Fig. 11. Typical Installation

Vermiculite
Infill

Flaunching

Short Length

or Flue Offset.

Of Flue Pipe,

18mm

Fig. 12. Thermostat Setting

Thermostat Flap

Locking Nut

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DX50iB 3/99

following points:

1. The bottom grate bars must all be
fitted and should move freely and
easily when the riddling mechanism is
operated.

2. The plates round the sides and back
of the grate must be in position and
sitting correctly.

3. The throat plate must be fitted in
the roof of the appliance -see Fig. 13.

4. Ensure that the over-run catch
swings freely and easily on its spindle
preventing the fire doors from closing
until the ashpit door has been shut.

COMMISSIONING

On completion of the installation and
after allowing a suitable period of
time for the fire cement and mortar to

Fig. 11.
In most installations it will be possible

to sweep the chimney through the
appliance. If this is not possible then
some alternative means (such as a soot
door), must be provided.

The free-inset method of installation
may be used instead of infilling.
Details are available on request.

THERMOSTAT

Before lighting the fire check the cold
setting distance of the thermostat.

With the control knob at the
maximum setting the flap should be
18 mm from the air inlet as shown in
Fig. 12. To adjust the distance slacken
the locking nut and adjust as
necessary. When set correctly
re-tighten the locking nut. Ensure that
the flap opens and closes freely as the
knob is turned.

ASSEMBLY

Fit the side panels, hood and top grid
onto the appliance. Instructions for
this are enclosed with the panel pack.

Replace any internal parts previously
removed.

PRE LIGHTING

CHECK

Before initial lighting check the

dry out, the fire should be lit and
checked to ensure that smoke and
fumes are taken from the appliance up
the chimney and emitted safely. Also
check all joints and seals.

The central heating pump should be
adjusted to give the correct water flow
against the circuit resistance and the
system should be correctly balanced.

On completion of the installation and
commissioning please leave the
operating instructions with the
customer and advise on the use of the
appliance and any controls on the
system.

Fig. 13. Throat Plate Position

Throat Plate

Upper Bracket
smokeless fuels)

(for burning

Lower Bracket
(for burning
coal, wood & peat)

in the Smokeless fuel position

The Throat Plate is shown

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DX50iB 3/99

610

168 i/d

(To Suit 150mm Flue Pipe)

Charnwood DX45iB & DX50iB

Overall Dimensions

(dimensions are in mm)

Boiler Tappings 1" BSP Female
2 On Each Side Of Boiler

620

400

240

261

250

360 120

147

547

520

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