Chesney's Alchemy GFL850URN, GFL850, GFP700 Swansnest, GFP700 Wigwam, GFP500 User And Installation Instructions Manual

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Technical Manual
PIN: 0558CO1462

User and Installation Instructions
Model No. GFL850URN

IMPORTANT:
Please read these instructions carefully before installation or use.

These instructions are only valid if the following country code is on the appliance.
If this code is not present on the appliance, it is necessary to refer to these
technical instructions which will provide the necessary information concerning
the modification of the appliance to the conditions of use for the country.

This appliance must be installed and serviced by a qualified person in accordance
with local and national regulations.

The flue system must be installed and inspected by a qualified person in
accordance with local and national regulations.

2

Contents

Section

Pages

1

Unpacking

3-4 2 Technical Data

5

3

Installation Parameters

6-7

4

Construction Information

8-12

5

Appliance Details

13-14

6

Preparing the Appliance for Installation

15-21

7

Installation

22-36

8

GV60 Control Information

37-48

9

Commissioning the Fire Unit

49-51

10

Briefing and Handover to the Customer

52

11

Servicing and Maintenance

53-61

12

Fault Finding

62

13

User Instructions

63-72

14

Installer Checklist

73

15

Dealer and Installer Information

73

16

Annual Service Record

74

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1. Unpacking

Remove the appliance from its packaging, check that it is complete and undamaged.
If satisfied by the condition and the contents is as specified, proceed with the installation.
The installation should only be carried out by a competent person and all gas work must be

carried out by a Gas Safe registered person in accordance with national and local regulations
for both gas and electricity (If required).

The installation must comply with local and national building regulations.
For the Republic of Ireland, reference should be made to IS813 and ICP3 and any guidance

notes from Bord Gais.
Failure to comply with the regulations nullifies ALL guarantees.

Parts

Fig. 1 Glass Fronted Appliance Fig. 2 Installation Manual / Warning Label

Fig. 3 Bronze Urn Fig. 4 Interior Panels

Fig. 5 Frame Fig. 6 4mm Ball Head allen Key

4

Fig. 7 Smoke Match Holder Fig. 8 Remote Control Handset

Fig. 9 Pressure Test and Isolation Valve

5

2. Technical Data

Gas Type

Natural Gas

Gas Connection Size

8.0mm O.D. tubing

Pilot Assembly

Seagas P4-41

Control System

Mertik Maxitrol GV60 (Radio Frequency)

Appliance Mass Range (kilograms)

Gas

Type

Gas Category, Type

and Supply Pressure

Countries of Destination

AT

BG

CH

CY

CZ

DE

DK

EE

ES

FI

FR

GB

GR

HR

IE

IT

LT

NG

I

2H

- G20 at 20mbar

      

     



Gas

Type

Gas Category, Type

and Supply Pressure

Countries of Destination

LU

LV

NO

PL

PT

RO

SE

Sl

SK

TR

NG

I

2H

- G20 at 20mbar

      



Appliance

Gas

Type

Gas Category, Type

and Supply Pressure

Injector

(1 per appliance)

Nominal Heat

Input

kW, (Gross)

Gas Rate

m3/h

Burner

Pressure

(mbar)

Efficiency

Class

Marking

Size

(Single

hole)

GFL850Urn

NG

I

2H

- G20 at 20mbar

1.80

1.8mm

5.80

0.552

17.9

2

Appliance

Efficiency

Net %

Gross %

GFL850Urn

74.7

67.3

Appliance

NOx

Class

NOx Concentration / Limits

mg/kWh

GFL850Urn 5 100

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3. Installation Parameters

This appliance must be installed in accordance with the rules in force, and used only in a
sufficiently ventilated space. Consult instructions before installation and use of this appliance.

NOTE - Wear protective clothing when fitting or carrying works out on the appliance.
For your safety it is law that all gas appliances must be installed by a competent person, in

accordance with the current gas safety regulations applicable in the country of use.
The installation must be carried out in accordance with the relevant local and national

specifications and comply with current Building Regulations.
If there is any conflict between these instructions and the current regulations, then the current

regulations are to be followed.
NOTE - The flue must not be shared with any other appliance.
If the chimney has been used for solid fuel, the chimney must be swept before installation.
The flue must be fitted in accordance with local and national regulations.
Damper plates or restrictor plates must not be fitted in the flue.
The flue system must be in good condition, meet all regulations and work correctly.
The flue must be inspected by a competent person and passed for use with the appliance.
It is advised that a flue specialist inspect the flue system on an annual basis to ensure that the

flue system is sound and the combustion products outlet (terminal) is clear of obstruction.

The flue kit should only be fitted to the appliance where the chimney serving the appliance:

a) Has passed a flue flow test to ensure that the flue is sound and without leaks; and
b) Has been swept if previously used for solid fuel.

The flue kit shall not be fitted to chimney that is likely to have problems with condensation, i.e. a
length in excess of 12m internal or 10m external to the building.

Do not install the appliance in a bathroom or a room that contains a bath or shower.
It is advised that provisions be made for the removal of the appliance without the need to

dismantle the flue system.
Before installation, ensure that the local distribution conditions (identification of the type of gas

and pressure) and the adjustment of the appliance are compatible.
Before the appliance is installed, the flue / chimney must be inspected to ensure that it is

structurally sound and free from obstructions.
Ensure the builders opening and supports are made of non combustible and heat resistant

material.
Do not cover the appliance and or do not wrap it in an insulation blanket or any other material
Do not make any changes to the appliance.
The gas connection must be in accordance with local and national regulations.

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This appliance is intended for use on a gas installation with a governed meter.
The pilot fitted to this appliance is not to be adjusted or put out of action. If the pilot is damaged

or faulty it should be replaced only with the original identical unit supplied by Chesney’s

Limited.

WARNING - SPILLAGE MONITORING SYSTEM

The appliance is fitted with a thermostatic switch (TTB), which is located in close proximity to
the draught diverter and operates to shut the appliance off if the evacuation of combustion
products is interrupted (for example caused by lack of flue pull or flue blockage). The TTB
MUST NOT be adjusted, modified or put out of action by the installer. The TTB MUST NOT be

removed or ‘bridged out’ for any reason. If the TTB is faulty and requires replacement, only

genuine Chesney’s parts should be used.

When using stone like materials and or plaster finishing, the chimney breast should dry for at
least 6 wks to prevent cracks.

The appliance is not fitted with an integral guard. It is recommended that a guard be used for
the protection of young children, the elderly or infirm and also for normal use conforming to
BS8423:2002, such that access to the hot appliance is minimised.

Do not place combustible materials directly in front of the appliance. Floor coverings, such as
carpets, are considered to be acceptable provided there is a gap of at least 225mm between
the top of the carpet and flame. Where no floor covering is present, it must be at least 300mm
from the finished floor to make allowances for any carpet or combustible floor covering which
may be fitted at a later date.

In case of a damaged or broken glass, do not use the appliance and isolate the gas to the
appliance.

Clean the glass before you use the appliance in order to prevent dirt from burning on the glass.
All appliances are supplied with a metal data plate attached to it and must remain with the

appliance for annual services.
The data plate is attached to a chain (see fig.11) and is placed in the air slot on the base of

the appliance (see fig. 10)
NOTE: DO NOT attempt to remove the data plate while the appliance is HOT!

Fig. 10 Fig. 11

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4. Construction Information

Hearths

The appliance does not require a hearth if the flame or any incandescent surface is more than
225mm above any floor covering or 300mm with no floor covering.

Any lower than this a hearth conforming to national regulations is required.

Emissions Exit Connection Types

The minimum chimney height is 2 meters from the spigot.
A smoke pellet can be used to test the flue for effectiveness of the draw, light the smoke pellet

and place to the base of the chimney / liner. Check other parts of the dwelling (including loft
areas) for leakage, down draught etc. If the smoke is drawn into the chimney / liner without
problem, continue with the installation.
If there is little or no flow into the chimney preheat the chimney and repeat the smoke test. If
there are still issues with the draw seek expert advice.

NOTE – The smoke test gives a fair idea on the draw, but is no guarantee that the products of
combustion from the appliance will clear. A spillage test is also required after the installation.

If spillage occurs after installation a flue liner may be required.

Conventional Class 1 Chimney

Fig. 12 Fig. 13

IMPORTANT NOTE ­If the appliance has been installed in a conventional Class 1 chimney with no liner the
debris shield must be used (see fig. 12) and the warning label (supplied in the manual)
must be fixed to the back of the data plate. (see fig.13)

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Fig. 14 4” (102mm) Flue Liner

If the appliance is fitted with a flue liner the debris shield will not be required (see fig.14).
NOTE – Leave enough flue length to allow connection. The minimum flue liner is 2 meters from

the spigot.

The Builders Opening

Use non combustible heat resistant materials for the chimney breast, including the top of the
chimney breast, the material in the chimney breast and the back wall of the chimney breast.
The construction must comply with all relevant regulations.

The appliance can be used with a sound Class 1 unlined flue with a minimum diameter of 7”
(178mm). If the appliance is used with a lined chimney the minimum flue diameter must be 6”
(152.4mm) or above to accommodate the 4” liner. (see fig. 15)

Fig. 15

Min 7” unlined / Min 6” lined Min 7” unlined / Min 6” lined

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Start with a builders opening. C is including plaster and skimming (see fig.16)

Appliance

A B C

D

E (Page11)

GFL850Urn

910mm

520mm

355mm

65mm

120mm

Fig. 16 Front elevation Side elevation

The appliance supports are approx. (For measurement ‘D’ See table above) Height 135mm x
Depth 355mm (Including plaster and skimming) (see fig.17)

Fig. 17 Front Elevation Side Elevation

The front filling is approx. Height 110mm x Depth 70mm including plaster and skimming (see
fig.18)

Fig. 18 Front Elevation Side Elevation

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Gas Route

For your safety it is law that all gas appliances must be installed by a competent person, in
accordance with the current Gas Safety regulations applicable in the country of use.

Ensure that the gas supply is capable of delivering the required amount of gas, and is in
accordance with the rules in force.

When laying the gas pipe work check the fire unit’s gas inlet location to ensure a smooth run.
Lay the appliance in the desired area to note where the appliance’s gas inlet location to ensure

a smooth run.
For ease the gas is best run to the left side of the appliance.
An isolation valve or valves must be fitted near to the appliance in an accessible area, meeting

all local and national regulations this is to allow the complete removal of the burner control
assembly, for maintenance or repair.

The best route for the gas is through the base of the appliance to the position shown in fig.19.
(For measurement ‘E’ See table on page 10)

Fig. 19 Top Elevation

If routed through the back of the appliance the position of the knock out plate is shown in fig.

20. (For measurement ‘E’ See table on page 10)

Fig. 20 Front Elevation

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Note – This appliance must not be used as part of the wall support structure.

Supports are to be made (see fig. 21) to ensure the appliance does not rest on
the lower tray, leave a gap of at least 20mm under the controls housing, 10mm around the

sides, top and at least 15mm at the back. This space is for the collection of debris.

Fig. 21

Front Elevation Side Elevation

Make sure that the appliance is not carrying the weight of the chimney breast.

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5. Appliance Details

GFL850Urn

Fig. 22

IMPORTANT NOTE – Allowances must be made for the battery compartment

Suggested opening size for stone slips behind the outer casing flange.

Appliance

Length

Height

GFL850Urn

910mm

410mm

Suggested opening size for stone slips in front of the outer casing flange.

Appliance

Length

Height

GFL850Urn

890mm

375mm

14

Fig. 23

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6. Preparing the Appliance for Installation

The appliance is supplied in an assembled state minus the Urn and interior panels these are
packed in separate boxes.

Important Notes

 Ensure the appliance is cold before undoing the glass fixings.
 Care must be taken when using the Allen key to prevent damage to paintwork.
 The glass is not bonded to the glass fixing bracket. Hold the glass and the bracket

when fitting to the appliance.

 Ensure the glass is clean on both sides before lighting as dirt; oils etcetera can etch the

glass.

 Do not clean with abrasive materials as this can accelerate dirt accumulation and

weaken the glass.

Fig. 24

Undo the five glass fixings at the top using the 4mm ball head allen key supplied (see fig. 25)

Fig. 25

16

Remove the 3 hex screws located at the bottom of the glass fixing (see fig. 26).

Fig. 26

IMPORTANT NOTE – The glass is not bonded to the glass fixing bracket. Hold the glass and
the bracket when removing from the appliance.

Lift the glass and bracket from the bottom and lift carefully out from the gap at the top
(see fig. 27)

Fig. 27

17

Remove the burner tray by undoing the 2 securing / levelling screws (see fig. 28).

Fig. 28

Carefully lift the burner from the appliance. NOTE – The burner bed fibre matting used to
spread the flame can irritate the skin when handled and is advised to wear protective clothing.
The fibre matting is also very fragile and must be handled with care to avoid damage.
IMPORTANT – Only use a soft brush to clean the surface. Do NOT use a vacuum to clean the
fibre bed (see fig. 29).

Fig. 29

Lift the burner base assembly to access the wiring.
IMPORTANT NOTE – The wiring attached to the burner base is also attached to the controls
housing below and must be disconnected to remove the burner base from the appliance (see
fig. 30, 31).

Fig. 30 Fig. 31

18

Disconnect the power lead, spark lead cable and 8 core cable from the controls box. (See fig.
32-35).

Fig. 32 Fig. 33

Fig.34 Fig.35

Undo the interrupter nut and pull out the cable / black grommet from the interrupter block. (See
fig. 36-38).

Fig.36 Fig.37

Fig.38

19

Lift the burner clear from the appliance (see fig. 39, 40).

Fig. 39 Fig.40

Carefully pull the base back plate out, the TTB bullet connections are threaded through the
plate hole (see fig. 41-44).
NOTE – The TTB bullet connections are supplied from Chesney’s factory disconnected to avoid
damage to the TTB and are to be connected during installation.

Fig. 41 Fig.42

Fig. 43 Fig.44

Remove the emissions diverters at each end of the appliance (see fig. 45-47).

Fig.45 Fig.46

20

Fig.47

Remove the screws to release the inner casing from the outer casing (see fig. 48)

Fig. 48

Carefully slide the inner casing out (see fig. 49)

Fig. 49

21

Place the outer casing on its back and remove the screws holding the controls housing then
remove the housing (see fig. 50, 51).

Fig. 50 Fig. 51

Remove the screws attaching the spigot and drop the spigot out (see fig. 52, 53).

Fig. 52 Fig. 53

Remove the screws holding the debris shield and drop the shield out (see fig. 54, 55).

Fig. 54 Fig. 55

The outer casing is ready to place in the constructed opening.

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7. Installation

IMPORTANT The outer casing must be sealed against the front face of the builders opening,

failure to do so may result in spillage problems.
There are 2 debris spacers attached to the back of the appliance and 2 spacers attached to the
base of the appliance (see fig. 56, 57) this ensures the distance of the debris void and must not
be removed.

Fig. 56 Fig. 57

Fit the outer casing in the opening and secure (see fig. 58-60).
There is no need to use all securing points.

Fig. 58 Fig. 59

Back Securing Points Front Securing Points

Fig. 60

Side Elevation