Flavel Caress, Slimline SC Installation And Maintenance Instructions Manual

Caress

Slimline SC

COAL EFFECT GAS FIRE

Installation and Maintenance Instructions

Hand these instructions to the user

Model No’s FNVC**SN is for use on Natural Gas (G20) at a supply
pressure of 20 mbar in G.B. / I.E.

** denotes trim & fret variant

CONTENTS

Section 1 Information and Requirements PAGE

1.0 Appliance Information 3

1.1 Conditions of Installation 4

1.2 Flue and chimney suitability 4

1.3 Fireplace / surround suitability 5

1.4 Shelf position 5

1.5 Chimney inspection 5-6

1.6 Fire place opening / catchment space 6

1.7 Fitting to Chair bricks 8

1.8 Precast Flues 8

1.9 Metal Flue boxes 8

1.10 Hearths 9

1.11 Spillage Monitoring System 9

Section 2 Installation of Fire

2.1 Unpacking the fire 10

2.2 Installing the fire box 10-16

2.3 Gas tightness and burner pressure 17

Section 3 Assembling Fuel Bed and Commissioning

3.1 Assembling the ceramics and fuel bed 18-21

3.2 Fitting the Caress trim 22

3.3 Fitting the fret 23

3.4 Lighting the appliance 24

3.5 Checking for clearance of combustion
products 25-26

Section 4 Maintenance

4.1 Removal of the Burner Assembly 27

4.2 Removal of the Battery Ignitor 28

4.3 Repacing the Battery 28

4.4 Removing the Oxy-Pilot Assembly 28

4.5 Replacing the Control Cable 29-30

This appliance is manufactured by:-

BFM Europe Ltd,
Trentham Lakes,
Stoke-on-Trent,
ST4 4TJ

2

SECTION 1

INFORMATION AND REQUIREMENTS

1.0 APPLIANCE INFORMATION

Model FNVC**SN ** denotes trim & fret variant
Gas Type G20

Main injectors (2 off) Size 235

Pilot Type S.I.T. Oxystop

YA OP 9055

Max. Gross Heat Input : 6.5 kW
Min. Gross Heat Input : 4.2 kW

Cold Pressure : 20.0 +/-1.0 mbar (G20)

Ignition : 1.5V Battery Generator

Electrode Spark Gap 4.0mm

Weight 15.5 kg Chrome, 16.5kg Brass

Fire box Dimensions (with trim fitted)

Width : (with standard trim, no spacer) 510mm
Height : (with standard trim, no spacer) 625mm
Depth : (overall-with fender) 140mm
Depth : Flush-fit (from mounting face to rear) 105mm

Gas Connection 8mm Compression (Supplied with fire)

Efficiency Declaration

The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2002 and the result is 51.5%.
The gross calorific value of the fuel has been used for this efficiency
calculation.
The test data from which it has been calculated has been certified by Advantica.
The efficiency value may be used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings.

3

INSTALLATION REQUIREMENTS

1.1 CONDITIONS OF INSTALLATION

In Great Britain :-

It is the law that all gas appliances are installed only by a CORGI Registered
Installer, in accordance with these installation instructions and the Gas Safety
(Installation and Use) Regulations 1998 as amended. Failure to install appliances
correctly could lead to prosecution. It is in your own interest and that of safety to
comply with the law.

The installation must also be in accordance with all relevant parts of the Local and
National Building Regulations where appropriate, the Building Regulations
(Scotland Consolidation) issued by the Scottish Development Department, and all
applicable requirements of the following British Standard Code of Practice.

1. B.S. 5871 Part 2 Installation of Inset Live Fuel Effect Gas Fires

2. B.S. 6891 Installation of Gas Pipework

3. B.S. 5440 Parts 1 & 2 Installation of Flues and Ventilation

4. B.S. 1251 Open fire place components

5. B.S. 715 Metal flue pipes for gas appliances

6. B.S. 6461 Part 1 Installation of Chimneys and flues

7. B.S. 1289 Clay Flue Blocks and Terminals

8. I.S. 813 : 1996 Domestic Gas Installation (Republic of Ireland)

In Republic of Ireland :-

No purpose made additional ventilation is normally required for this
appliance, when installed in G.B. When Installing in I.E. please consult doc­ument I.S. 813 : 1996 Domestic Gas Installation, which is issued by the
National Standards Authority of Ireland. If installing in Northern Ireland,
please consult local building regulations. Any purpose made ventilation
must be checked periodically to ensure that it is free from obstruction.

1.2 FLUE AND CHIMNEY SUITABILITY

This appliance is designed for use with conventional brick built or lined chimneys
and fabricated flues. It is also suitable for use with pre-cast flue blocks conforming
to B.S. 1289 and metal flue boxes conforming to BS 715. All flues must conform
to the following minimum dimensions.

Minimum diameter of circular flues 125 mm (Without Flue

Restrictor Fitted)
Minimum effective height of all flue types 3 metres
When fitting to conventional chimneys or 175mm flues it may be desirable to
fit the flue restrictor baffle (supplied) to reduce the flue flow and increase the
efficiency of the fire. Safe clearance of products must always be checked by
carrying out a smoke match test as described.

4

1.3 FIREPLACE / SURROUND SUITABILITY

The fire must only be installed on a hearth it must not be installed directly onto
carpet or other combustible floor materials.

The fire is suitable for fitting to non-combustible fire place surrounds and propri-

etary fire place surrounds with a temperature rating of at least 150oc.

If a heating appliance is fitted directly against a wall without the use of a fire
surround or fire place all combustible material must be removed from behind
the trim. Soft wall coverings such as blown vinyl, wall paper etc. could be
affected by the rising hot air and scorching and/or discoloration may result.
Due consideration should be made to this when installing or decorating.

1.4 SHELF POSITION

The fire may be fitted below a combustible shelf providing there is a minimum dis­tance of 200mm above the top of the fire and the shelf does not project more than
150mm. If the shelf overhangs more than 150mm the distance between the fire
and the shelf must be increased by 15mm for every 25mm of additional overhang
over 150mm.

1.5 FLUE / CHIMNEY INSPECTION

Before commencing installation, a flue or chimney should be inspected to ensure
that all the following conditions are satisfied.

1. Check that the chimney / flue only serves one fire place and is clear of any

obstruction. Any dampers or register plates must be removed or locked in
the open position.

2. Brick/stone built chimneys or any chimney or flue which has been used for

an appliance burning fuel other than gas must be thoroughly swept. The
base of the chimney / flue must also be thoroughly cleared of debris etc.

3. Any under-floor air supply to the fire place must be completely sealed off.

4. Ensure that the inside of the chimney / flue is in good condition along it’s

length and check that there is no leakage of smoke through the structure
of the chimney during and after the smoke pellet test. With pre-cast flues

it is especially important to check the inside of the flue for extruded
cement / sealant protruding from the joints between the flue
blocks. If present, these should be removed by rodding the flue
before proceeding with the installation.

5. Using a smoke pellet, check that there is an up-draught in the chim

ney / flue and that the smoke can be seen issuing from the terminal /
chimney pot outside.

5

There must be no leakage of smoke through the structure of
the chimney during or after the smoke pellet test and it is
important to check inside upstairs rooms adjacent to the chimney /
flue. Check the chimney pot / terminal and general condition of the

brickwork or masonry. If the chimney or flue is in poor condition or if
there is no up-draught do not proceed with the installation. If there is a
history of down-draught conditions with the chimney / flue, a tested and
certificated flue terminal or cowl suitable for the relevant flue type should
be considered.

6. A spillage test must always be carried out during commissioning of

the appliance.

1.6 FIRE PLACE OPENING AND CHIMNEY CATCHMENT SPACE

The front opening of the fire place must be between 330 and 430 mm wide, and
between 550 and 565mm high. If the opening exceeds these dimensions then a
surround must be constructed from suitable non-combustible material to produce a
correct size opening. Any surround must be suitably sealed to the fire place to
prevent leakage. See below in fig.1

When installing into a brick built chimney, you must ensure that there is sufficient
depth to accomodate any debris which may fall from the chimney. This depth
must be sufficient to accomodate 12 litres of volumetric space.

Fire Opening

330mm Minimum
430mm Maximum

610mm
Minimum

520mm Minimum

Fig. 1

550mm Minimum
565mm Maximum

Minimum Flat
Sealing Area

6

Table A - Installation Depth Requirements for a Flavel Caress Slimline SC
being installed into a brick built chimney, requiring 12.0 litres of debris
collection volume (fig. 2)

330 (minimum opening width) 183
340 178
350 173
360 170
370 167
380 163
390 158
400 155
410 151
420 146
430 (maximum opening width) 143

For example, if the appliance was to be fitted into a 400mm wide opening, the
depth required would be 189mm. See fig. 2 below for explanatory diagram.

Fig. 2

7

Opening Width ( e.g. 400mm)

Depth Required

(e.g. 155mm)

1.7 FITTING TO FIREPLACES WITH EXISTING CHAIRBRICKS AND
CONVENTIONAL BRICKBUILT CHIMNEYS

This appliance is suitable for use in fireplaces fitted with an existing chairbrick
without the need for removal of the chairbrick, providing the minimum depth of the
fireplace exceeds 190mm. If the depth is less than 190mm then the spacer
(optional) must be used to give a minimum clearance from the rear of the fire to
the rear of the chairbrick of at least 90mm to allow sufficient space for the collec­tion of debris which may fall down the chimney. The fireplace must be checked to
ensure that no part of the chairbrick is within 50mm of the flue outlet of the fire
when installed.

1.8 FITTING TO PRE-CAST FLUE INSTALLATIONS

When installing this appliance into pre-cast flues, always ensure that the
spigot restrictor baffle has been removed.

To install the fire box in to pre-cast flue starter blocks, there must be at least
120mm from the mounting face of the fire to the rear of the pre-cast flue
starter block to allow sufficient space for debris collection. It is important to

consider this depth when choosing a fire surround as the thickness of the fire
surround must be sufficient to give a total depth of at least 120 mm to the rear of
the starter block, otherwise there will be insufficient depth. To increase this depth
the fire surround may be packed away from the wall using suitable
non-combustible board, providing the installation is correctly sealed. If in doubt
about the suitability of the fire contact BFM Europe for advice before proceeding.
It is important to ensure that the pre-cast flue is in good condition and is free from
extruded mortar or sealant from between the flue blocks.

This appliance has been tested for use in a pre-cast flue block complying
with BS EN 1858. In accordance with BS EN 1858, pre-cast flues built with
directly plastered faces (front or rear) are not correctly installed as to ensure
proper operation with any type of gas fire. In some instances of this flue
construction, temperature cracking of surface plaster may occur through no
fault of the appliance. An air gap or some form of insulation material should
be installed to prevent normal flue temperatures from damaging wall
surfaces.

1.9 FITTING TO PRE-FABRICATED TWIN WALL METAL FLUE BOXES

The appliance may be fitted to twin wall metal flue boxes conforming to the con­structional requirements of BS 715, (for example the Selkirk LFE 125 box). The
box must have a minimum flue diameter of 125mm internal and minimum internal
dimensions of 160mm deep by 580mm high by 350mm wide. There are no maxi­mum dimensional requirements for the box. The top face of the box must be
insulated with a minimum thickness of 50mm of non-combustible mineral wool
insulation or similar material. The flue box must stand on a non-combustible base
of minimum thickness 12mm.

8

1.10 HEARTHS

This appliance must only be installed on to a concrete or non-combustible hearth.
The hearth material must be a minimum thickness of 13mm with the top surface at
least 50mm above the floor. The hearth must be fitted symmetrically about the fire
opening and have a minimum width of 760mm and a minimum projection of
300mm forwards from the fire opening.

1.11 SPILLAGE MONITORING SYSTEM

This appliance is fitted with an atmosphere sensing spillage monitoring system in
the form of an oxygen sensing pilot. This is designed to shut the fire off in the
event of a partial or complete blockage of the flue causing a build up of combus­tion products in the room in which the fire is operated. The following are impor-
tant warnings relating to this spillage monitoring system :-

1) The spillage monitoring system must not be adjusted by the installer.

2) The spillage monitoring system must not be put out of operation.

3) When the spillage monitoring system is exchanged only a complete original
manufacturers part may be fitted. It is not possible to replace individual parts on
the pilot system on this appliance, only a complete pilot assembly (including the
thermocouple) may be fitted.

9

SECTION 2

INSTALLATION OF FIRE

2.1 UNPACKING THE FIRE

Carefully lift the fire out of the carton. Remove the loose item packaging carefully
from the front of the appliance. Check the contents as listed :-

Packing Check List

1 off Fire box / burner assembly
1 off Cast trim
1off Fret / Ashpan
1 off Boxed ceramic base, 2 piece ceramic front rail 11 synthetic coals
1 off each User instruction book and Installation book
1 off Flue restrictor baffle (for use in brick built chimneys and large diameter

e.g. 175mm flue applications).

Fixing Kit Check List

2 off Fixing cables
4 off Wallplugs
4 off Eyebolts
2 off Tensioner bolts & nuts
2 off Tensioner screws
4 off Cast trim brackets & screws

2.2 INSTALLING THE FIRE BOX

Establish which type of flue you are intending to install the fire in to :-

225 x 225mm (9 inch x 9 inch) brick built chimneys
175mm (7 inch) diameter lined brick or stone flue, or insulated pre-fabricated
metal flue box to B.S. 715.

When installing into 125mm (5 inch) diameter lined brick or stone flue, or
insulated pre-fabricated metal flue box to B.S. 715 and pre-cast flues the
restrictor baffle must not be fitted.

A spillage test must always be carried out to check satisfactory
clearance of flue products, regardless of the type of flue the
appliance is being fitted to.

10

To remove the burner, proceed as follows:

a) Remove the trim, which is secured by two screws at the bottom L/H &

R/H sides of the trim. Remove the burner heat shield from the front of
the fire box to allow access to the burner. See fig. 3 below.

Fig. 3

b) Ensure that the hearth is protected from damage and carefully lift the

fire box into the fire opening, then slide it back into position. Check that
the fire box flange fits flush to the sealing face of the fire surround or
wall with no gaps present.

c) Remove the burner. To allow burner removal, the control lever operat

ing cable must be removed. The control lever operating cable can be
seen running across the base of the fire, below the burner. To release
the cable, unscrew the cable securing screw located in the centre of the
aluminium operating arm and pull the cable out from its fixing hole.
Release the other end of the cable by pushing the cable forwards to the
right, i.e. into the operating arm so as to release the tension. Pull the
cable nipple out of the retaining hole and remove the cable through the
slot in the operating arm. See fig. 4 overpage

11

Fig. 4

d) Unscrew the burner assembly fixing screws at either side of the firebox,

and the two fixing screws at the base of the fire (See fig. 5 below).
Carefully pull the base of the burner forwards from the fuel-bed
support panel. The burner can now be removed from the appliance.

Fig. 5

12

Continue for all models

Whilst the fire box is still in position, decide which side the gas supply is to enter
the fire from. If concealed pipe work is required plan the pipe run to enter the fire
box through one of the openings in the sides of the fire box below the fuelbed sup­port panel and connect to the isolating / inlet elbow. The gas connection to the
appliance should be made to the isolating / inlet elbow using 8mm rigid tubing.
There must be no soldered joints within the firebox. See fig. 6a & 6b below for
suggested concealed pipe layouts.

Fig. 6a

Fig. 6b

Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound.

Carefully withdraw the fire box from the opening to enable the gas supply and fire
fixing to be completed.
There is a choice of methods of fixing the firebox which are provided to enable the
installer to deal with any type of installation.

13

Firebox

Fireplace

Builders
Opening

Gas Supply

Firebox

Approx.
40mm

Fireplace

Gas Supply

Approx.
40mm

IMPORTANT : Sealing of the Gas Unused Gas Pipe Inlet Apertures

In line with current CORGI regulations, it is imperative that the gas supply inlet
apertures that are not utilised during the installation are sealed with the foil
tape as supplied. Failure to seal these inlet apertures could lead to flame

reversal, which in turn will damage the burner and control systems of the product.
Fig. 7 below shows a correctly sealed installation.

Fig. 7

PLEASE NOTE :-

14

Seal off unused gas inlet

apertures and cable fixing holes

as shown

Only holes to be left are the specifically
sized air relief holes as indicated by the
labels positioned by them and the gas
inlet aperture that is used

BFM EUROPE LTD. WILL NOT BE LIABLE FOR
GUARANTEE CLAIMS THAT ARE AS A DIRECT
RESULT OF THE UNUSED GAS INLET APERTURES
NOT BEING CORRECTLY SEALED.

The preferred method of fixing which is suitable for almost all situations is
the cable fixing method which is described in the following section in detail.

To fit using the preferred cable method proceed as follows-

e) Mark out and drill 4 off No 14 (6mm) holes in the back face of the fire

opening in the positions shown below in fig. 8

Fig. 8

Fit the wallplugs provided and screw the fixing eyes securely into the rear of the
fire opening. If the clearance at the rear of the fire is at the minimum specified for
a precast flue application, it may be necessary to bend over the lower fixing eyes
after screwing them fully in to the rear of a pre-cast starter block.

f) Uncoil the two fire fixing cables and thread one end of each of the

cables through one of the two holes on each side of the flue outlet
shroud.

g) Position the fire carefully on the (protected) surface of the hearth and

reach into the fire opening. Thread each of the cables vertically
downwards through the pair of fixing eyes on the same side of the fire.
Thread the free end of the cables through the corresponding circular
hole on each side of the lower rear of the fire. Carefully slide the fire
box back into the fire opening and pull both cables tight.

h) Thread a tensioning screw over each of the cables and ensure that the

tensioning nut is screwed fully up against the hexagon shoulder of the
tensioning screw (this provides maximum travel for the tensioning nut).

i) Fit a screwed nipple on to each of the cables and pull hand tight up

against the tensioning screw, then secure each nipple with a flat
bladed screwdriver. See fig. 9 overpage.

20mm

500mm

Fireplace Opening

100mm

250mm

15

Fig. 9

j) Evenly tighten the tensioning nuts to tension both cables and pull the

fire snugly against the wall. Do not overtighten, it is only necessary to
pull the seal up against the sealing face of the wall, it does not need to
be compressed. Check that there are no gaps behind the seal.

k) With the fire securely in place, if a concealed gas connection has been

made through either of the access holes in the sides of the fire, the
holes should be closed around the pipe to prevent leakage of air
through the gap around the pipe.

l) Refit the burner. Fit the four retaining screws and check that the burner

is correctly locked into position. On slide control models refit the control
cable To do this, firstly locate the nipple on one end of the cable into
recess in operating arm and then secure the front part of the operating
arm back onto the rear of the operating arm with the retained screw.

This should not be overtightened. Move the control lever fully
downwards and check that the left hand micro-switch operates the
igniter and that the control valve spindle is fully depressed. Move the
control lever upwards to the “off” position and check that the right hand
(cut-off) micro-switch operates. Check that the control lever operates
smoothly and safely.

16

NOTE : The cable is factory set, and therefore should need no adjustment

m) Refit the front burner heat shield to the sides of the fire box (2 Screws)

n) Before making the final gas connection, thoroughly purge the gas

supply pipework to remove all foreign matter, otherwise serious
damage may be caused to the gas control valve on the fire.

The other firebox fixing method is as follows :-

In installations where the cable method is not suitable (e.g. loose masonary in rear
of fire opening) the firebox can be secured to the fire surround using four screws
and wall plugs provided. Below (fig.10) is a diagram to indicate the hole centre
positions available on the firebox to facilitate the screw fixing to the fireplace /
surround.

Fig. 10

17

430mm

300mm

133mm

Firebox
Mounting
Flange

420mm

2.3 GAS TIGHTNESS AND INLET PRESSURE

a) Remove the pressure test point screw from the inlet elbow pressure test

point and fit a manometer.

b) Turn on the main gas supply and carry out a gas tightness test.

c) Depress the control lever to the position marked pilot. Hold down the

control lever for a few seconds to purge the pipe work. The burner
should light, continue to hold the control lever for a few seconds to latch
the slide valve then lift to the full-on position.

d) Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-

0.4 in w.g.)

e) Turn off the fire, remove the manometer and refit the pressure test point

screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.

18

3.1 ASSEMBLING THE CERAMICS AND FUEL BED

a) Place the fuel-bed base centrally on to the fuelbed support and pull

fully forwards to the burner. Make sure that the fuelbed base is

located centrally in the fire box. Ensure that the fuelbed base is
not lodged on the burner. See fig. 11 below.

Fig. 11

b) Place the left hand front coal rail moulding onto the front ceramic rail

support as shown below in Fig. 12

Fig. 12

19

NOTE : The position of the fuel-bed components are critical to the
performance of the product. Therefore please ensure that the fuel-bed
components are positioned as described in the following section prior to
requesting a service call due to soot build up, poor flame pattern etc.

c) Place the right hand front coal rail moulding onto the front ceramic rail

support as shown below in Fig. 13

Fig. 13

d) Fit four large coals behind the ceramic front rails as shown below in

Fig. 14

Fig. 14

20

e) Select three of the small coals and fit onto the ribs of the fuel-bed base.

See fig. 15 below

Fig. 15

f) Select the remaining four small coals and arrange along the rear of the

fuelbed, directly behind the third row of coals. See fig. 16 below.

Fig. 16

21

g) Ensure the coals sizes are correctly positioned as shown in Fig 17

below. “L” denotes “large” coals and “S” denotes small coals. If any
coals are missing, please contact your retailer. Do not proceed with

the installation.

Fig. 17

h) Ensure the flame paths are un-interrupted as shown below in Fig. 18. If

necessary, make minor adjustments to the coal positions to ensure

the flame paths indicated by the arrows are available.

Fig. 18

Warning : Use only the coals supplied with the fire. When replacing the

coals remove the old coals and discard them. Fit a complete set of
coals of the correct type. Do not fit additional coals or any coals
other than a genuine replacement set.

22

L

L

L

L

S

S S

S

S

S

S

To ensure that the release of fibres from these R.C.F (Refractory Ceramic
Fibre) articles is kept to a minimum, during installation and servicing we
recommend that you use a HEPA filtered vacuum to remove any dust
accumulated in and around the appliance before and after working on the
appliance. When replacing these articles we recommend that the replaced
items are not broken up, but are sealed within heavy duty polythene bags,
clearly labelled as “RCF waste”. RCF waste is classed as a “stable”, non
reactive hazardous waste and may be disposed of at a landfill licensed to
accept such waste Protective clothing is not required when handling these
articles, but we recommend you follow the normal hygiene rules of not
smoking, eating or drinking in the work area, and always wash your hands
before eating or drinking.

3.3 FITTING THE TRIM - CARESS MODELS ONLY

a) Fit the 4 off mounting brackets supplied with the fire in the loose items

pack to the rear face of the Cast-Iron Trim as shown below in Fig. 19

Fig. 19

23

4 off Mounting
Brackets

b) Fit the fascia to the firebox by hooking the mounting brackets into the

slots on the firebox as indicated in Fig. 20

Fig. 20

3.3 FITTING THE FRET

a) Remove the fret & ashpan cover from the packaging.

b) Place fret up to the front radiused section of the fuelbed, taking care

not to move coal positions.

c) Place ashpan cover under fret assembly and centralise.

24

Image shows
bottom right hand
slot, further slots
are position on
mounting flange at
opposite side and
top L/H / R/H
mounting flanges

3.4 LIGHTING THE APPLIANCE

a) Turn on the isolation valve. Depress the control lever fully downwards

to the position marked. Hold down the control lever for a few seconds to
allow the gas to reach the pilot.

b) The fire will then begin its ignition sequence. If the pilot does not light,

continue to press the control lever until ignition occurs. The pilot flame
can be seen by looking underneath the front ceramic rail, above the
burner heat shield, at the front left hand side of the fuelbed. When the
pilot has lit, continue to hold the control lever down for 5-10 seconds to
allow the thermocouple to heat up, before releasing the lever apply one
firm downwards push to ensure that the f.s.d. valve is fully latched, if
the pilot goes out when the control lever is released, repeat the lighting
sequence.

c) After lighting, move control lever up to the high position and the main

burner will light. It is recommended that for the most efficient
performance the fire is allowed to warm up for a few minutes with
control lever set to high.

d) The gas control can be moved from the High to Low position to give the

desired heat output.

e) To turn the fire off, FULLY raise the control lever to the OFF position.

WARNING : If the fire goes out for any reason or is turned off and it

is necessary to re-light the fire it is important to allow the
fire to cool for 3 minutes before attempting to re-light it.

3.5 CHECKING FOR CLEARANCE OF COMBUSTION PRODUCTS

a) Close all doors and windows in the room.

b) Light the fire and allow to run for approximately 5 minutes on high

position.

c) After approximately 5 minutes hold a smoke match just inside and

below the centre of the lower front edge of the top of the fire. (It is
recommended that a suitable smoke match holder is used when check
ing for clearance of combustion products). All smoke generated should
be drawn back into the flue. If slight spillage occurs or if in doubt,
repeat the test after a further 5-10 minutes. If the test indicates that

spillage is occurring and the flue restrictor baffle has been fitted, it
should be removed and the test repeated after the fire has cooled.

25

d) If spillage persists, the flue is not functioning correctly and a fault exists.

If, after investigation the fault cannot be traced and rectified, the fire
must be disconnected from the gas supply and expert advice obtained.

e) If there is an extractor fan fitted any where in the vicinity of the

appliance, or in adjacent rooms the spillage test should be repeated
with the fan running on maximum and all interconnecting doors open.

f) After ensuring that the fire is safe to use it should be left on high

position to fully warm up. During this time a slight odour may be
noticed, this is due to the “newness” of the fire and will soon disappear.

At this stage any minor adjustments to the coals should be made using
suitable long handled tongs and taking care not to damage the coals.

Finally, hand the Installation and Maintenance Instructions and the
Users Instructions over to the customer and explain the operation of the
fire.

26

SECTION 4

MAINTENANCE

Servicing Notes

Servicing should be carried out annually by a competent person such as a CORGI
registered engineer. This is a condition of the Flavel guarantee schemes.
The service should include visually checking the chimney and fire opening for
accumulations of debris and a smoke test to check for a positive up-draught in the
chimney.
The condition of the coals should be checked and if necessary the whole set

should be replaced with a genuine replacement set.

The burner assembly is designed to be removed as a complete unit for ease of
access. After any servicing work a gas tightness check must always be

carried out.

4.1 Removal of the burner assembly

4.1.1 Prepare the work area (lay down dust sheets etc,)

4.1.2 Lift the fender and ash pan cover out of the way and put them in a safe

location. Remove all of the loose coals and front ceramic rail. Remove
the trim. Unscrew the two pozi-drive fixing screws which secure the
burner heat shield and remove it from the fire.

4.1.3 Isolate the gas supply and remove the inlet pipe from the appliance inlet

elbow. To allow burner removal, the control lever operating cable must
be removed. The control lever operating cable can be seen running
across the base of the fire, below the burner. To release the cable,
unscrew the cable securing screw located in the centre of the aluminium
operating arm and pull the cable out from its fixing hole. Release the
other end of the cable by pushing the cable towards the right i.e. into
the operating arm so as to release the tension. Pull the cable nipple out
of the retaining hole and remove the cable through the slot in the
operating arm. Remove the two retaining screws at the base of the
burner unit, and the screw each side of the burner unit. The base of the
burner unit can now be pulled forward, allowing the burner to be
removed from the fire box. Remove the burner assembly from the fire.

4.1.4 Refit the burner assembly to the firebox by carefully pushing the bottom

of the burner back into position. Secure using the two screws into the
side frame of the firebox, and two screws into the base.

27

4.1.5 It is now necessary to refit and correctly tension the operating cable. To

do this, first set the control lever to the horizontal (central position), this
is the position which creates maximum tension in the operating cable.
Refit the operating cable to the aluminium operating arm, firstly locating
the nipple on one end of the cable into recess in operating arm and
then feed the other end through hole in operating arm. Pull the operat
ing cable until it is finger tight and secure with screw into operating arm
(do not over-tighten). Move the control lever fully downwards and check
that the left hand micro-switch operates the igniter and that the control
valve spindle is fully depressed. Move the control lever upwards to the
“off” position and check that the right hand (cut-off) micro-switch
operates. Check that the control lever operates smoothly and safely.

4.2 Removal of the battery ignitor

4.2.1 Remove the burner assembly as above.

4.2.2 Disconnect the ignition lead and earth lead from the igniter. Unscrew the

Battery retaining cap and place battery to one side. Then unscrew
igniter retaining ring and remove igniter from panel.
Re-assemble in reverse order and carry out a gas tightness test.

4.3 Replacing the battery

4.3.1 Unscrew Battery retaining cap situated at the front right of the fire and

remove the battery

4.3.2 Replace in the reverse order using a 1.5V AA Alkaline Battery.

4.4 Removing the Oxy-Pilot Assembly

Note: Because this appliance is fitted with an atmosphere sensing ‘Oxy­Pilot’ it is not possible to replace the thermocouple separately, because the
thermocouple position is factory set to a tight tolerance. Any replacement of
parts on the pilot requires a complete new pilot assembly.

4.4.1 Remove the burner assembly as in section 4.1

4.4.2 Unscrew and remove the thermocouple retaining nut from the end of the

control tap, disconnect the ignition lead from the pilot electrode and the
two inline leads from the microswitch.

4.4.3 Unscrew and remove the two pozi-drive screws which secure the pilot

assembly to the burner. Remove the pilot.

4.4.4 Re-assemble in reverse order and carry out a gas tightness test.

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4.5 Replacing the Control Cable

4.5.1 The control lever operating cable can be seen running across the base

of the fire, below the burner. To release the cable, unscrew the cable
securing screw located in the centre of the aluminium operating arm
and pull the cable out from its fixing hole. Release the other end of the
cable by pushing the cable towards the right i.e. into the operating arm
so as to release the tension. Pull the cable nipple out of the retaining
hole and remove the cable through the slot in the operating arm. See
fig. 21 below.

Fig. 21

4.5.2 Hold the hexagonal control lever cable locking bush with a spanner

and unscrew the locking screw using a 2mm allen key to release the
cable from the control lever. The control cable can now be removed
from the cable guide tubes.

4.5.3 To fit the replacement cable, thread the end of the new cable into the

long length of p.t.f.e. sleeve (as supplied) , taking care not to kink the
sleeve. Now carefully feed the sleeve and cable into the left hand cable
guide tube until the ends emerge above the control lever. Now thread
the short length of p.t.f.e. sleeve over the end of the cable and thread
the sleeve and cable into the top of the short cable guide tube.

4.5.4 When the end of the cable emerges from the short cable guide tube,

locate the nipple on the other end of the cable into the locating hole in
the aluminium operating arm. Thread the free end of the cable into the
cable retaining hole on the operating arm, but at this stage do not
tighten the securing screw.

29

4.5.5 Fit the hexagonal control lever cable locking bush onto the control

lever and fit the control cable loosely into the bush in the gap between
the two lengths of p.t.f.e. sleeve. Ensure that the cable is located in the
retaining hole in the locking bush and tighten the screw sufficiently to
retain the cable but still allowing it to slide for adjustment.

4.5.6 It is now necessary to correctly tension the operating cable. To do this,

first set the control lever to the horizontal (central position), this is the
position which creates maximum tension in the operating cable.

Pull the free end of the operating cable through the operating arm until it
is finger tight and secure with screw into operating arm (do not over
tighten).

4.5.7 Slide the operating arm fully to the right hand position and hold in

position, slide the control lever relative to the cable until the cable
retaining screw lines up with the hole in the spacer frame. This sets the
control lever in the correct position. Hold the hexagonal locking bush
with a spanner and tighten the retaining screw using the 2mm allen key.
Move the control lever fully downwards and check that the left hand
micro-switch operates the igniter and that the control valve spindle is
fully depressed. Move the control lever upwards to the “off” position
and check that the right hand (cut-off) micro-switch operates. Check
that the control lever operates smoothly and safely.

PARTS SHORTLIST

Replacement of any other parts must be carried out by a competent person such
as a CORGI registered gas installer.
The part numbers of the user replaceable parts are as follows, these are available
from specialist spares stockists whose details can be found on our web site,
www.bfm-europe.com, in the ‘stockist’ section.

Fuelbed base B-96400
Fuelbed front rails (pair) B-96410
Replacement coal set B-96420
Complete ceramic set (base, front rails and coals) B-96430
ODS Pilot Assy. (NG) B-19660
ODS Pilot Assy. (LPG) B-19670
Ignition Wire B-34690
L/H fibre board 20-20050
R/H fibre board 20-20060
Rear fibre board 20-16660

30

Due to our policy of continual improvement and development the exact
accuracy of illustrations and descriptions contained in this book cannot be
guaranteed

Part No. B-118880

Issue 2

BFM Europe Ltd.

Trentham Lakes

Stoke-on-Trent

Staffordshire

ST4 4TJ

www.bfm-europe.com

Telephone - General Enquiries : [phone]
Telephone - Service : [phone]