Flavel Expression HE Installation, Maintenance & User Instructions

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Expression HE

INSET LIVE FUEL EFFECT GAS FIRE

Installation, Maintenance & User Instructions

Hand these instructions to the user

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

** denotes trim and fret variant

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CONTENTS

Section 1 Information and Requirements PAGE

.0 Appliance Information 3

.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 6-7

1.7 Fitting to metal flue boxes 7

1.8 Fitting to pre-cast flues 8

1.9 Spillage monitoring system 8

1.10 Wall / hearth mounting 9

Section 2 Installation of Fire

2.1 Unpacking the fire 10

2.2 Installing the fire box 10-18

2.3 Gas tightness and inlet pressure 18

Section 3 Assembling Fuel Bed and Commissioning

3.1 Assembling the ceramics and fuel bed 19-23

3.2 Connecting the battery pack 24

3.3 Fixing the infra-red eye 25

3.4 Lighting the appliance 26

3.5 Fitting the Expression fascia 27

3.6 Checking for clearance of combustion products 27

Section 4 Maintenance

4.1 Removal of the burner assembly 28

4.2 Removing the remote gas valave 29

4.3 Removing the Oxy-Pilot assembly 29

4.4 Repacing the batteries 30

Section 6 User Instruction Section

6.1 Conditions of Installation & about your new fire 32-33

6.2 Operating the fire 34

6.3 Remote handset malfunction 35

6.4 Re-assembling the ceramics and fuel bed 36-40

6.5 Cleaning the fire 40

6.6 Cleaning the fuel-bed / glass panel 40-41

6.7 Removal & re-fitting the Expression fascia 41

6.8 User replaceable parts 41

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SECTION 1

INFORMATION AND REQUIREMENTS

1.0 APPLIANCE INFORMATION

Model FHKCEHRN

Gas Type G20

Main injectors (2 off) Size 130

Pilot Type Copreci 21100 / 162 (RC)

Max. Gross Heat Input : 4.5 kW

Min. Gross Heat Input : 3.5 kW

Cold Pressure : All models 20.0 +/- 1.0 mbar

Ignition : 9V battery generator (RC models)

Electrode Spark Gap 4.5mm Nominal

Weight 22.5 kg

Fire box Dimensions (with Expression fascia fitted)

Width : (with Expression fascia) 500mm Height : (with Expression fascia) 643mm Depth : (overall-without fender) 180mm Depth : Flush-fit (from mounting face to rear) 180mm

Gas Connection 8mm Compression (Supplied with fire)

This appliance is manufactured by :-

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

Efficiency Declaration

The efficiency of this appliance has been measured as specified in BS 7977-1 : 2002 and the result is 70%. 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 GL Industrial Services UK Ltd. The efficiency value may be used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.

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INSTALLATION REQUIREMENTS

1.1 CONDITIONS OF INSTALLATION

It is the law that all gas appliances are installed only by a 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. BS 5871 Part 2 Installation of Inset Fuel Effect Gas Fires

2. BS 6891 Installation of Gas Pipework

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

4. BS 1251 Open fire place components

5. BS 715 / BS EN 1856-2 Metal flue pipes for gas appliances

6. BS 6461 Part 1 Installation of masonary chimneys and flues

7. IS 813 : 1996 Domestic Gas Installation (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. In Scotland, please consult the current edition of the Building standards regulations, issued by the Scottish Executive. 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 and metal flue boxes conforming to BS 715 / BS EN 1856-2. 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 4 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.

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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 proprietary fire place surrounds with a

temperature rating of at least 150oc. (Class “O”)

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 securely 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.

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

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

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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 370 and 450 mm wide, and between 550 and 570mm 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 figure 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

370mm Minimum 450mm Maximum

580mm Minimum

470mm Minimum

Fig. 1

550mm Minimum 570mm Maximum

Minimum Flat Sealing Area

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Table A - Installation Depth Requirements for a Flavel Expression HE being installed into a brick built chimney, requiring 12.0 litres of debris collection volume (figure 2)

When installing this product into a brick built chimney, there must be a minimum depth available of 200mm available for the collection of debris behind the firebox when installed.

See figure 2 below for explanatory diagram.

Fig. 2

1.7 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 175 box). The box must have a minimum flue diameter of 125mm internal and minimum internal dimensions of 275mm deep by 580mm high by 400mm wide. 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 if the flue box being utilised is of single skin construction.

Firebox

Depth Required

200mm

Minimum

VOID FOR FLUE DEBRIS COLLECTION

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1.8 FITTING TO PRE-CAST FLUES

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 180mm 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 180 mm to the rear of the starter block, otherwise there will be insufficient depth. If in doubt about the suitability of the fire contact the manufacturer for advice before proceeding. This

fire has been designed to fit standard 100mm pre-cast starter blocks with 3 inch rebated false chimney breast and a 10mm plaster wall covering. 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 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 important 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.

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1.10 WALL / HEARTH MOUNTING

This appliance must be fitted on a flat, non-combustible base of minimum thickness 12mm. In addition, a non-combustible hearth or physical barrier should be provided in front of the fire.

With “hole in the wall” type installations, where it may be desirable not to fit a hearth panel or physical barrier, the product may be installed in accordance with Document J of the building regulations so that every part of the flame or incandescent material is at least 225mm above the floor level. For the customers safety, and in accordance with BS 5871-2, the fitting of a hearth panel or physical barrier should be carried out. Should this advice not be followed however, please give consideration to the safety of the occupants in the room to which the appliance is installed.

Any hearth panel or physical barrier that is fitted should project a mnimum of 300mm forwards from the fire opening and 150mm either side of the fire opening, as shown below in Fig. 3 Any physical barrier must be securely fixed and be of robust design.

Fig. 3

Example of Wall Mounted Physical / Tactile Barrier

Example of Floor Mounted Physical Barrier i.e. Hearth Panel

Fireplace Opening

300mm Minimum

150mm Minimum each

side of fireplace

opening

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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 Boxed ceramic base, front ceramic rail and 7 coals 1 off Loose items bag including remote handset and 6AA batteries and 1 off 9V battery on RC models. 1 off Flue restrictor baffle 1 off Installation & Maintenance / User Instruction Book (Combined)

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, insulated pre-fabricated metal flue box to BS 715 / BS EN 1856-2. When installing into 125mm (5 inch) diameter lined brick or stone flue, or insulated pre-fabricated metal flue box and liner to BS 715 / BS EN 1856-2 the restrictor baffle must not be fitted.

The flue restrictor baffle (supplied in the loose items) should only be used in 225 x 225mm (9 inch x 9 inch) brick built chimneys where the flue pull is excessive. It must not be fitted if installing the product into a metal flue box, pre-cast or 125mm diameter lined flue. See fig 4 / 5 below for details on fitting / removing the restrictor baffle onto the spigot on the rear of the firebox.

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.

Fig 4 - Flue Restrictor Baffle Not Fitted

Fig 5 - Flue Restrictor Baffle Fitted via 3 screws as shown

3 screws

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Proceed as follows :-

a) Remove the top glass retaining cover from the product. It is secured via

the two screws as indicated. See figure 6 below.

Fig. 6

b) Remove the left and right hand side glass securing brackets from the

product. They are secured via 3 off screws each side. See figure 7 below.

Fig. 7

2 off securing screws

3 off securing screws L/H/S

3 off securing screw R/H/S

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c) Lift the glass panel forwards and clear from the firebox, taking care not

to damage the glass panel. See figure 8 below.

Fig. 8

d) Remove the burner heat shield, which is retained by 2 off screws as

shown below in figure 9.

Fig. 9

Burner Heat

Shield Retaing

Screws

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For all Remote Control models proceed as follows :-

e) Remove the two off screws from the left and right hand burner

mounting brackets, plus the two screws from the base of the control panel as shown below in figure 10, this will allow removal of the complete burner unit from the firebox.

Fig. 10

4 off burner

retaining screws

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Continue as follows :-

f) 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 or rear 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 figure 11 & 12 below for suggested concealed pipe layouts.

Fig. 11

Fig. 12

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.

Firebox

Fireplace

Builders Opening

Gas Supply

Firebox

Approx. 40mm

Fireplace

Gas Supply

Approx. 40mm

Builders Opening

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IMPORTANT : Sealing of the Gas Unused Gas Pipe Inlet Apertures

In line with current 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. Figure 13 below shows a correctly sealed installation.

Fig. 13

PLEASE NOTE :-

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.

Seal off unused gas inlet

apertures as shown

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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-

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

opening in the positions shown below in figure 14.

Fig. 14

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.

h) 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.

i) 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.

j) 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).

k) 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 figure 15 overpage.

20mm

500mm

Fireplace Opening

100mm

250mm

Page 17

Fig. 15

l) 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.

m) 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.

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

burner is correctly locked into position.

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

and secure the trim to the fire using the magnets provided.

p) 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.

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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 (figure 16) is a diagram to indicate the hole centre positions available on the firebox to facilitate the screw fixing to the fireplace / surround.

Fig. 16

2.3 GAS TIGHTNESS AND INLET PRESSURE (REMOTE CONTROL

MODELS).

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

manometer.

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

c) Depress both the round buttons on the handset. The fire will then

commence its ignition sequence and will light to high. See page 24 for full details of the operating method for the fire.

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.

512mm

260mm

50mm

Firebox Mounting Flange

426mm

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SECTION 3

ASSEMBLING FUEL BED AND COMMISSIONING

3.1 ASSEMBLING THE CERAMICS AND FUEL BED - COAL MODELS

a) Place the ribbed ceramic fuelbed base on top of 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 fit fully down onto the fuel bed support and is not lodged on the burner. Ensure the air ports as indicated by the arrows are not blocked by the fuel-bed matrix. See figure 17 & 18 below.

Fig. 17

Fig. 18

Check air ports in fuel-bed base panel are not obstructed. If these air ports are not in line with the holes in the fuelbed base matrix do not

proceed with the installation

Air ports in Fuelbed base mounting panel

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.

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b) Position the front ceramic coal support onto the burner support as

shown below in figure 19.

Fig. 19

c) Fit the front row left hand coal as shown below in figure 20.

Fig. 20

ositioning of front ceramic coal support onto burner

upport

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d) Fit the front row left hand side central coal as shown below in

figure 21.

Fig. 21

e) Fit the front row right hand side central coal as shown below in

figure 22.

Fig. 22

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f) Fit the front row right hand coal as shown below in figure 23.

Fig. 23

g) Fit the rear row of 3 coals as shown below in figure 24.

Fig. 24

The exact position and fit of the coals may be very finely adjusted to give the most pleasing and random appearance.

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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.

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.

h.) Replace the glass panel and retaining trims as described on

pages 11 & 12

NEVER USE THE FIRE WITHOUT THE GLASS PANEL IN POSITION, OR IF BROKEN OR CRACKED.

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3.2 CONNECTING THE BATTERY PACK (Remote Control Models)

a) To prevent un-necessary battery drain, the battery pack that is

used to provide the remote control function for this product is disconnected at the factory. Prior to attempting to light the product, can the installer please ensure that the battery pack is re-connected as shown in section b), & c) below.

b) Locate the battery pack in the support cradle at the bottom R/H side of

the firebox / burner assembly.

c) The wire and connecting plug from the battery pack should then be

connected into the supply wire running from the control board. See figure 26 below.

Fig. 26

Battery

Pack

Connecting Wire

Connecting Plug

Note : Ensure that the battery pack is re-fitted correctly into itʼs mounting cradle

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3.3 FIXING THE INFRARED SENSOR IN POSITION

a) The infrared eye as shown below in figure 27 is supplied on a flying

lead, the self adhesive pad should be used to secure the infrared eye to the Expression fascia as shown in figure 28, the handset will require line of sight to the infrared eye to ensure correct operation.

Fig. 27

b) Remove the backing paper from the self adhesive pad and position the

infrared eye in the air channels in the bottom of the fascia, so that the infrared eye is flush with the front edge of the fascia, as shown below in figure 28. Check the operation of the handset, as detailed in section 3.3 and adjust the position of the infrared eye if necessary.

Fig. 28

Infrared Eye Flying Lead

Infrared Eye Sensor

Self Adhesive Pad

Final position of infrared eye

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3.4 LIGHTING THE APPLIANCE

a) The Remote control handset generates an infrared signal, which will be

received by the sensor situated at the front right of your fire, behind the black controls cover. This infrared signal requires direct line of sight from the handset to the sensor on the fire to ensure good operation.

b) To light the appliance using the handset, point the handset at the fire

and press the 2 left hand buttons together. The fire will emit a “beep” sound, the buttons can now be released. After a few seconds an audible clicking can be heard and then the fire will light the pilot and then light the main burner. The ignition cycle will take approximately 20 seconds.

c) To reduce the level of heat input on the fire, point the handset at the fire

and press the small flame button.

d) To increase the level of heat input on the fire, point the handset at the

fire and press the large flame button.

e) To leave the fire in the standby mode (pilot only running) press the small

round button on the handset.

f) To switch the appliance off completely, press the large round button on

the handset, the fire will then switch off. See figure 25 for image of handset.

Fig. 25

Off Button

High (Large Flame)

Low (Small Flame)

Standby Button

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3.5 FITTING THE EXPRESSION FASCIA

a) Hook the fascia onto the top mounting bracket fitted to the firebox b) The bottom of the fascia is retained by magnets fitted to the lower

retaining brackets.

3.6 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 as shown at the bottom of the page in figure 29 (It is recommended that a suitable smoke match holder is used when checking 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.

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

Fig. 29

Smoke Match Position -

Approximately 10mm

inside the centre of the

draught divereter.

Page 28

SECTION 4

MAINTENANCE

Servicing Notes

Servicing should be carried out annually by a competent person such as a registered engineer. This is a condition of the Flavel extended guarantee

schemes. The service should include changing the oxypilot as a condition of the guarantee and 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.

Remote Control Fires - For Diagrams refer to section 2

4.1 Removing the RC Burner Assembly

4.1.1 Prepare work area (lay down dust sheets etc.)

4.1.2 Remove the trim. Lift the fender and ash pan cover out of the way and

put them in a safe location. Isolate the gas supply. Remove the glass panel, unscrewing the top and side retaining brackets, see page 10 & 11 of this manual for information. Carefully lift clear the glass panel. Remove the coals, front ceramic from the rail and fuel-bed base matrix. Remove all of the loose coals and front ceramic rail. Unscrew the two pozi-drive fixing screws which secure the burner heat shield and remove it from the fire.

4.1.4 Unscrew the 4 off burner retaining screws on the side brackets, the

burner should then be lifted out of the firebox.

NOTE

: Please take care with the wiring loom

4.1.5 To refit the burner assembly, re-assemble in reverse order and carry out

a gas tightness test. Refit the burner heat shield then refit the coals referring to section 3 for the correct coal layout. Refit the glass panel and glass panel retaining trims. The fender and ash pan cover or fascia can now be re-positioned.

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4.2 Removing the Remote Gas Valve from the fire

4.2.1 Prepare work area (lay down dust sheets etc.)

4.2.2 Remove the burner assembly as described in section 4.1.

4.2.3 Disconnect pilot, main and injector pipes and disconnect the wiring loom

thermocouple and ignition wire, the valve can then be removed. Re-assemble in reverse order, refit the burner heat shield then refit the coals referring to section 3 for the correct coal layout. Refit the glass panel and glass panel retaining trims. The fender and ash pan cover or fascia can now be re-positioned.

4.3 Removing the 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.

4.3.1 Prepare work area (lay down dust sheets etc.)

4.3.2 Remove the burner assembly as described in section 5.1.

4.3.3 Loosen the pilot nut and remove the two screws retaining the pilot

assembly. Unscrew the thermocouple from the gas valve.

4.3.4 Re-assemble in reverse order, refit the burner heat shield then refit the

coals referring to section 3 for the correct coal layout. Refit the glass panel and glass panel retaining trims. The fender and ash pan cover or fascia can now be re-positioned.

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4.4 Replacing the Batteries

4.4.1 Prepare work area (lay down dust sheets etc.)

4.4.2 Remove the trim / fret & ashpan cover.

4.4.3 The battery pack is located on the right hand side of the product, below

the burner assembly. Slide the battery pack out, and replace the batteries as necessary.

4.4.4 The fender and ash pan cover or fascia can now be re-positioned.

NB The handset uses one LR61 (9v) and should be replaced by

removing the cover on the rear of the handset.

ENSURE THE BATTERIES ARE CONNECTED TO THE CORRECT POLARITY POSITVE (+), NEGATIVE (-)

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PARTS SHORTLIST

Replacement of parts must be carried out by a competent person such as a registered gas installer. The part numbers of the replaceable parts are as follows, these are available from your local stockist, whose details may be found on the BFM Europe website, address as per rear page.

Complete coal / ceramic set B-121600 Coal fuelbed base B-121550 Coal fuelbed front rail B-121560 Replacement coal set B-121610 Glass panel B-125630 ODS pilot B-49710 Remote control valve B-106790 Remote control board B-106800 Remote battery cable B-106810 Battery holder B-106820

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SECTION SIX - USER INSTRUCTIONS

6.1 INSTALLATION INFORMATION

CONDITIONS OF INSTALLATION

It is the law that all gas appliances are installed only by a competent (e.g. Registered) Installer, in accordance with the installation instructions and the Gas Safety (Installation and Use) Regulations 1998. 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 fire may be fitted below a combustible shelf provided that the shelf is at least 200mm above the top of the appliance and the depth of the shelf does not exceed 150mm.

The fire may be installed below combustible shelves which exceed 150mm deep providing that the clearance above the fire is increased by 15mm for each 25mm of additional overhang in excess of 150mm.

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

If the chimney or flue has been previously used by appliances burning fuels other than gas they must be swept prior to the installation of this fire.

If this appliance is fitted directly on to a wall without the use of a fireplace or surround, soft wall coverings such as wallpaper, blown vinyl etc. could be affected by the heat and hot convection air and may discolour or scorch. This should be considered when installing or decorating.

The Model number of this appliance is as stated on the rating plate affixed to the control panel of the fire and the appliance is manufactured by:-

BFM Europe Ltd Trentham Lakes Stoke on Trent ST4 4TJ

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ABOUT YOUR NEW EXPRESSION HE (High Efficiency) GAS FIRE

The Flavel Expression High Efficiency coal effect gas fire incorporates a unique and highly developed fuel bed which gives the realism of a loose coal layout combined with realistic flames and glow. The use of durable ceramic material in the construction of the fuelbed components ensures long and trouble free operation. When first using your new fire a slight smell may be noticed. This is due to starch used in the manufacture of the soft ceramic coals, it is non-toxic and will soon disappear. Please take the time to fully read these instructions as you will then be able to obtain the most effective and safe operation of your fire.

IMPORTANT SAFETY INFORMATION

WARNING

This appliance has a naked flame and as with all heating appliances a fireguard should be used for the protection of children, the elderly and infirm. Fireguards should conform to B.S. 8423 : 2002 (Fireguards for use with gas heating appliances).

It is important that this appliance is serviced at least once a year by a registered gas installer and that during the service the fire is removed from the fire opening and the chimney or flue visually checked for fallen debris or blockages which must be removed. The chimney should also be checked to ensure clearance of flue products. We recommend that during the annual service, replacement of the Oxypilot is carried out. This is a condition of the manufacturers guarantee.

After installation or during servicing a spillage test must always be carried out.

Rubbish of any type must NEVER be thrown onto the fuel bed, this could affect safe operation and damage the fire. Any debris or deposits should be removed from the fuel bed from time to time. This may be carried out by referring to the cleaning section as described later in this book. Only the correct number and type of coals or pebbles must be used and only complete and genuine replacement sets must be used. Always keep furniture and combustible materials well clear of the fire and never dry clothing or items either on or near to the fire. Never use aerosols or flammable cleaning products near to the fire when it is in use.

The ceramic fuel bed remains hot for a considerable period after use and sufficient time should be allowed for the fire to cool before cleaning etc.

The fire must only be operated with a fender which meets the criteria described in the rear of this book.

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6.2 OPERATING THE FIRE

a) The Remote control handset generates an infrared signal, which will be

b) To light the appliance using the handset, point the handset at the fire

c) To reduce the level of heat input on the fire, point the handset at the fire

and press the small flame button.

d) To increase the level of heat input on the fire, point the handset at the

fire and press the large flame button.

e) To leave the fire in the standby mode (pilot only running) press the small

round button on the handset.

f) To switch the appliance off completely, press the large round button on

the handset, the fire will then switch off. See figure 1 for image of handset.

Fig. 1

Off Button

High (Large Flame)

Low (Small Flame)

Standby Button

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6.3 TURNING THE PRODUCT OFF IN THE UNLIKELY EVENT OF A

REMOTE HANDSET MALFUNCTION.

a) In the unlikely event of the remote control handset malfunctioning (or if

lost or broken) after the appliance has been turned on, the fire can be turned off via the emergency shut off switch on the control panel.

b) To turn the product off, firstly remove the ashpan from the fire.

c) Press and hold the emergency shut off switch until the fire shuts down.

The process may take up to sixty seconds to complete, (see figure 2 below).

d) When the fire has shut down, release the emergency shut off switch.

e) The appliance will now remain in the “off” position until activated by the

remote handset.

Fig. 2

REPLACING THE BATTERIES (REMOTE CONTROL MODELS ONLY)

ENSURE THE FIRE IS COOL BEFORE REPLACING BATTERIES

Remove the ashpan cover. The battery pack is located on the right hand side side of the burner unit at the bottom. Carefully remove the pack and remove batteries. Replace in the reverse order using 6 off 1.5V AA Alkaline Battery. It is important that only an alkaline battery is used, otherwise premature battery failure and leakage may result.

Emergency Shut Off Switch Position on Control Panel.

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6.4 RE-ASSEMBLING THE CERAMICS AND FUEL BED

a) Remove the glass panel and retaining trims as detailed on page 11 &

12. Place the ribbed ceramic fuelbed base on top of 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 fit fully down onto the fuel bed support and is not lodged on the burner. Ensure the air ports as indicated by the arrows are not blocked by the fuel-bed matrix. See figure 3 & 4

below.

Fig. 3

Fig. 4

Check air ports in fuel-bed base panel are not obstructed. If these air ports are not in line with the holes in the fuelbed base matrix do not

proceed with the installation

Air ports in Fuelbed base mounting panel

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b) Position the front ceramic coal support onto the burner support as

shown below in figure 5.

Fig. 5

c) Fit the front row left hand coal as shown below in figure 6.

Fig. 6

ositioning of front ceramic coal support onto burner

upport

Page 38

d) Fit the front row left hand side central coal as shown below in

figure 7.

Fig. 7

e) Fit the front row right hand side central coal as shown below in

figure 8.

Fig. 8

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f) Fit the front row right hand coal as shown below in figure 9.

Fig. 9

g) Fit the rear row of 3 coals as shown below in figure 10.

Fig. 10

The exact position and fit of the coals may be very finely adjusted to give the most pleasing and random appearance.

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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.

h.) Replace the glass panel and retaining trims as described on

pages 11 & 12

NEVER USE THE FIRE WITHOUT THE GLASS PANEL IN POSITION, OR IF BROKEN OR CRACKED.

6.5 CLEANING THE FIRE - WARNING

Before attempting any cleaning operation ensure that the fire has been allowed to fully cool. The chrome effect Expression fascia supplied with the fire should only also be cleaned with a clean, damp cloth. The fascia is best cleaned in position on the fire when the appliance is not running and is cool. Black painted metal parts should be gently cleaned with a damp cloth.

6.6 CLEANING THE FUEL-BED / GLASS PANEL

We do not recommend cleaning of the coals or fuelbed components as these are fragile and damage may result. None of these parts must be washed or exposed to any cleaning agents or water. Any damaged parts must be replaced by contacting your dealer or telephoning BFM Europe Ltd. on the number stated on the rear cover of this book. The coals must only be replaced with a complete and genuine replacement set and the fire must never be run with the wrong number or damaged coals. The fuel-bed must be carefully re-assembled as stated in section 6.4

To clean the glass panel, please remove it from the product as described in pages 10-11. Use a clean damp cloth and ceramic glass cleaner to remove any stains or deposits frm the glass panel. Do not using scouring pads as this may scratch the surface finish of the glass panel.

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PLEASE NOTE :- The glass will require cleaning periodically. Condensation produced by the products of combustion will create marks on the inside face of the glass panel.

6.7 REMOVAL AND RE-FITTING THE EXPRESSION FASCIA

a) Hook the fascia onto the top mounting bracket fitted to the firebox

b) The bottom of the fascia is retained by magnets fitted to the lower

retaining brackets.

6.8 USER REPLACEABLE PARTS

The only user replaceable parts on this fire are the fuelbed components and coals which may be replaced as described in section 6.4. In order to replace the fuel-bed components, the glass panel of the appliance will need to be removed, please refer to pages 11 & 12 of this book for details on how to remove the glass panel.

Replacement of any other parts must be carried out by a competent person such as a registered gas installer. The part numbers of the user replaceable parts are as follows, these are available from BFM Europe Ltd. who may be contacted at the number on the rear cover of this book.

Complete coal / ceramic set B-121600 Coal fuelbed base B-121550 Coal fuelbed front rail B-121560 Replacement coal set B-121610 Glass panel B-125630

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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-160510

Issue 2

BFM Europe Ltd.

Trentham Lakes

Stoke-on-Trent

Staffordshire

ST4 4TJ

www.bfm-europe.com

Telephone - General Enquiries : (01782) 339000 Telephone - Service : (0844) 7700169