Formosa Fires Java Installation, Maintenance & User Instructions

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DECORATIVE FUEL EFFECT GAS FIRE

Installation, Maintenance & User Instructions

Hand these instructions to the owner following installation, they must be retained for future reference.

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

** denotes trim and fret variant fitted to product

CONTENTS

Section 1

1.0

Information and Requirements Appliance Information

PAGE

1.1

Conditions of Installation

1.2

Flue and chimney suitability

1.3

Fireplace / surround suitability

1.4

Shelf position

1.5

Chimney inspection

1.6

Fire place opening / catchment space

6-7

1.7

Fitting to chair bricks

1.8

Precast flues

1.9

Metal flue boxes

1.10

Hearths

1.11

Spillage monitoring system

Section 2

Installation of Fire

2.1

Unpacking the fire

2.2

Installing the fire box

10-16

2.3

Gas tightness and burner pressure

16-17

Section 3

Assembling Fuel Bed and Commissioning

3.1

Assembling the ceramics and fuel bed (Coal models)

17-19

3.2

Assembling the ceramics and fuelbed (Pebble models)

19-20

3.3

Assembling the ceramics and fuelbed (Driftwood models)

21-26

3.4

Fitting the trim / contemporary fascia

3.5

Fitting the fret

3.6

Lighting the appliance

3.7

Checking for clearance of combustion products

Section 4

Maintenance

4.1

Removal of the burner assembly

4.2

Removal of the piezo igniter

4.3

Removal of the control tap

4.4

Removal of the thermocouple

Section 5

User Instructions Section

5.1

Conditions of installation / about your new gas fire

32-33

5.2

Operating the fire

5.3

Assembling the coal fuelbed

35-36

5.4

Assembling the pebble fuelbed

37-38

5.5

Assembling the driftwood fuelbed

39-44

5.6

Cleaning the fire

5.7

Fitting the trim / contemporary fascia

5.8

Fitting the fret

This appliance is manufactured by :BFM Europe Ltd. Trentham Lakes, Stoke-on-Trent, ST4 4TJ.

SECTION 1

INFORMATION AND REQUIREMENTS

1.0 APPLIANCE INFORMATION

Model ASRC**MN

** denotes trim & fret variant of product Gas Type G20 Main injector (1 off) Size 440 Burner Type Aeromatic Self Vitiating Tubular Burner Max. Gross Heat Input : 6.5 kW

Min. Gross Heat Input & Ignition Rate : 2.2 kW

Cold Pressure : 20.0 +/-1.0 mbar Ignition : Push-button Piezo Electrode Spark Gap 4.0mm Packed Weight (All models with fret) 12.5 kg

Packed Weight (All models with contemporary trim) 10.5 kg Fire box dimensions (with standard trim fitted) Width : (with standard trim) 498mm

Height : (with standard trim) 600mm Depth : (from mounting face to rear panel) 120mm

Gas Connection : 8mm Compression (Supplied with fire)

Appliance Efficiency Declaration The efficiency of this appliance has been measured as specified in

BS 7977-1 : 2002 and the result is 51%. 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 BSI. The efficiency value may be used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.

INSTALLATION REQUIREMENTS

1.1 CONDITIONS OF INSTALLATION

It is the law that all gas appliances are installed only by a GAS SAFE 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 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. E.N. 1858 Chinmeys Components & Concrete Flue Blocks

8. I.S. 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. 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 BS EN 1858 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 leave the flue restrictor baffle (supplied) in place 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.

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.

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

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. 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 440 mm wide, and between 550 and 575mm 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

Fig. 1

355mm Minimum

Fire Opening

Minimum Flat Sealing Area

550mm Minimum 575mm Maximum

600mm Minimum

330mm Minimum 440mm Maximum

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.

Table A - Installation Depth Requirements for a Formosa Fires Java being installed into a brick built chimney, requiring 12.0 litres of debris collection volume (figure 2).

Opening Width (mm) Minimum Depth Required (mm)

330 (minimum opening width)

152

340

149

350

146

360

144

370

142

380

139

390

137

400

135

410

132

420

130

430

127

440 (maximum opening width)

125

For example, if the appliance was to be fitted into a 400mm wide opening, the depth required would be 135mm. See figure 2 below for explanatory diagram.

Fig. 2

Depth Required

(e.g. 135mm)

Opening Width ( e.g. 400mm)

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 175mm. If the depth is less than 175mm then the chairbrick must be removed. 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. This is held in place on the spigot by 2 screws.

To install the fire box in to pre-cast flue starter blocks, there must be at least 125mm from the mounting face of the fire to the rear of the pre-cast flue starter block to allow sufficient space for debris collection. If this dimension is

less than 125mm then a fire surround with a deeper rebate to increase the depth to at least 125mm from the mounting face of the fire. 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 125 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 Formosa Fires 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.

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 12mm 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 burner. 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.

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 and 7 synthetic coals 1 off Loose items bag. 1 off Trim or contemporary fascia (dependent upon model chosen) 1 off Boxed Fret & ashpan cover (dependent upon model chosen) 1 off Installation / User 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, 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.

Proceed as follows :- a) Remove the two screws at the bottom of the control panel. See figure 3

below

Fig. 3

2 burner retaining screws

b) The base of the burner unit can now be lifted, lift the two retaining

tabs on the burner brackets from the back of the firebox, allowing the burner to be removed. See figure 4 below

Fig. 4

Retaining Tabs on burner

c) 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.

d) 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 5a & 5b below for suggested concealed pipe layouts.

Fig. 5a

Gas Supply

Firebox

Approx. 40mm

Fireplace

Fig. 5b

Gas Supply

Firebox

Approx. 40mm

Fireplace

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.

IMPORTANT : Sealing of the Gas Inlet Apertures In line with current regulations, it is imperative that the gas supply inlet

aperture that is utilised during the installation is sealed with the grommet as supplied in the loose items pack. The product is manufactured with 3 knock

out gas inlets in the firebox wrap to allow a left hand, right hand or rear gas inlet supply to the inlet elbow. Using a hammer and a blunt chisel, remove the inlet aperture selected and then seal with the grommet supplied. To provide access for the gas supply pipe, cut the grommet with a sharp knife. Failure to seal the inlet apertures could lead to flame reversal, which in turn will damage the burner and control systems of the product.

Figure 6 below shows a correctly sealed installation. Fig. 6

Grommet fitted and cut to provide access for the gas supply pipe.

PLEASE NOTE :-

WE WILL NOT BE LIABLE FOR GUARANTEE CLAIMS THAT ARE AS A DIRECT RESULT OF THE GAS INLET APERTURE NOT BEING CORRECTLY SEALED WITH THE GROMMET PROVIDED.

There is a choice of methods of fixing the firebox which are provided to enable the installer to deal with any type of installation.

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.

The fire may be secured using the cable method as described below, or alternatively, in installations where the cable method is not suitable (eg. loose masonary in rear of fire opening) the fire box can be directly secured to the fire surround using the screws and rawlplugs provided.

To fit using the preferred cable method proceed as followse) Mark out and drill 4 off No 14 (7mm) holes in the back face of the fire

opening in the positions shown below in figure 7.

Fig. 7

500mm

325mm

100mm

Fireplace Opening

20mm

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 figure 8 below

Fig. 8

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 or rear 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 two retaining screws and check that the burner

is correctly locked into position.

m) 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 (figure 9) is a diagram to indicate the hole centre positions available on the firebox to facilitate the screw fixing to the fireplace / surround.

Fig. 9

300mm

Firebox Mounting Flange

520mm

140mm

430mm

2.3 GAS TIGHTNESS AND INLET PRESSURE 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 the control knob and turn anti-clockwise to the position marked

ignition / low. Hold in the control knob for a few seconds to purge the

pipe work then press the igniter button. The burner should light,

continue to hold the control knob for a few seconds then turn 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.

SECTION 3

ASSEMBLING FUEL-BED AND COMMISSIONING

3.1 ASSEMBLING THE FUEL-BED - Coal Fuelbed Model

a) Place the fuelbed base centrally on to the fuelbed support and push

fully backwards to the rear face of the fibre boards Make sure that the

fuelbed base is located centrally in the fire box. See figure 10

below. Fig. 10

b) Position the front row of four loose coals along behind the first row of

coals, ensuring that the flame paths as indicated are not interupted.

See figure 11 below Fig. 11

c) Fit the remaining three coals onto the ribs in the fuelbed as shown

below, ensuring that the rear flame paths as indicated are not interupted

See figure 12 below.

Fig. 12

The exact position and fit of the coals may be finely adjusted to give the best appearance.

Warning : Use only the coal set 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.

3.2 ASSEMBLING THE FUEL-BED - Pebble Fuelbed Model

a) Place the fuelbed base centrally on to the fuelbed support and push

fully backwards to the rear face of the fibre boards Make sure that the

fuelbed base is located centrally in the fire box. See figure 13

below. Fig. 13

b) Position the front row of four large loose pebbles along behind the first

row of pebbles, ensuring that the flame paths as indicated are not

interupted. See figure 14 below Fig. 14

Beige Pebbles to be Positioned as shown

c) Fit the three small pebbles onto the ribs in the fuelbed as

shown below, ensuring that the rear flame paths as indicated are

not interupted. See figure 15 below. Fig. 15

Beige Pebbles to be positioned as shown

The exact position and fit of the pebbles may be finely adjusted to give the best appearance.

Warning : Use only the pebble set supplied with the fire. When replacing the

pebbles remove the old pebbles and discard them. Fit a complete

set of pebbles of the correct type. Do not fit additional pebbles or

any pebbles other than a genuine replacement set.

21 21

3.3 ASSEMBLING THE FUEL-BED - Driftwood Fuelbed Model a) Place the fuelbed base centrally on to the fuelbed support and push

fully backwards to the rear face of the fibre boards Make sure that the

fuelbed base is located centrally in the fire box. See figure 16

below. Fig. 16

b) Position the piece of driftwood with the letter “A” stamped onto the

bottom face of it in the position at the left-hand side of the fuelbed

matrix. Ensure the positioning grooves as shown are on the top face of

the piece of driftwood. See figure 17 below. Fig. 17

Driftwood Piece “A”

Grooves in top face as detailed in sectrion b)

22 22

c) Position the piece of driftwood with the letter “B” stamped onto the

bottom face of it in the position at the centre of the fuelbed

matrix. Ensure the positioning grooves as shown are on the top face of

the piece of driftwood. See figure 18 below. Fig. 18

Driftwood Piece “B” Grooves in top

face as detailed in sectrion c)

d) Position the piece of driftwood with the letter “C” stamped onto the

bottom face of it in the position at the right-hand side of the fuelbed

matrix. Ensure the positioning grooves as shown are on the top face of

the piece of driftwood. See figure 19 below. Fig. 19

Driftwood Piece “C”

Grooves in top face as detailed in sectrion d)

23 23

e) Position the piece of driftwood with the letter “D” stamped onto the

bottom face of it in the position at the right-hand side of the fuelbed

matrix. Ensure this piece of driftwood is located into the groove in the

front right hand side of the fuelbed matrix . See figure 20 below. Fig. 20

Driftwood Piece “D”

Locating groove for driftwood piece “D” in front right hand side of fuelbed matrix

f) Position the piece of driftwood with the letter “E” stamped onto the

bottom face of it in the position at the front centre of the fuelbed

matrix. Ensure this piece of driftwood is located into the groove on

driftwood piece “C” . See figure 21 below. Fig. 21

Driftwood Piece “E”

Locating groove for driftwood piece “E” in centre of driftwood piece “C” and in front section of fuelbed matrix

24 24

g) Position the piece of driftwood with the letter “F” stamped onto the

bottom face of it in the across the centre of the driftwood pieces “A”,

“B” & “C”. Ensure this piece of driftwood is located into the groove’s on

the top face of driftwood pieces A, B & C . See figure 22 below. Fig. 22

Driftwood Piece “F” Locating grooves

for driftwood piece “F” in centre of driftwood piece “A”, “B” & “C”

h) Position the piece of driftwood with the letter “G” stamped onto the

bottom face of it in the across the left hand side of the fuelbed matrix,

locating into the grooves on driftwood pieces “A” & “B”. See figure 23

below. Fig. 23

Driftwood Piece “G” Locating grooves

for driftwood piece “G” in top of driftwood piece “A” &

“B”

25 25

Warning : Use only the driftwood set supplied with the fire. When replacing the driftwood remove the old driftwood pieces and discard them. Fit a complete set of driftwood pieces of the correct type. Do not fit additional driftwood or any driftwood pieces other than a genuine replacement set.

THE FOLLOWING STATEMENT IS APPLICABLE TO ALL FUEL-BED TYPES This appliance uses fuel effect pieces containing Refractory Ceramic Fibres

(R.C.F.), which are man-made vitreous silicate fibres. Excessive exposure to these materials may cause temporary irritation to eyes, skin and respiratory tract. Consequently, it makes sense to take care when handling these articles to ensure that the release of dust is kept to a minimum. To ensure that the release of fibres from these R.C.F. articles is kept to a minimum, during installation & servicing we recommend that you use a HEPA filtered vacuum to remove any dust and soot accumulated in and around the fire, before and after working on the fire. When replacing these articles we recommend that the replaced items are not broken up, but are sealed within a heavy duty polythene bag, clearly labelled as “RCF waste”. This is not classified as “hazardous waste” and may be disposed of at a tipping site licensed for the disposal of industrial waste. Protective clothing is not required when handling these arrticles, but we do 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.

This appliance does not contain any component manufactured from asbestos or asbestos related products.

26 26

IMPORTANT INFORMATION REGARDING FUELBED POSITION ON COAL, PEBBLE & DRIFTWOOD MODELS.

d) Before continuing with the installation, ensure

that the fuelbed is located behind the locating

tabs as shown below in figure 24, not on top of

the locating tabs as shown in figure 25.

Fig. 24 - Shows correct location of fuelbed

Fuelbed correctly positioned behind locating tabs

Fig. 25 - Shows incorrect location of fuelbed

Fuelbed incorrectly positioned on top of the locating tabs

27 27

3.4 FITTING THE TRIM / CONTEMPORARY FASCIA

a) Fit the outer trim assembly to the firebox with the magnets

provided.

3.5 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.

NOTE : Some models in this range are not supplied with a fret from the

factory, therefore please consult your local retailer for fitting

advice on the type of fret supplied with these models.

28 28

3.6 LIGHTING THE APPLIANCE (All models) a) Turn on the gas isolation tap. b) Depress the control knob and turn anti-clockwise to the position

marked ignition / low rate. Hold in the control knob for a few seconds to

purge the pipe work. c) Continue to hold-in the control knob and press the igniter button. If the

burner does not light, continue to press the igniter button until ignition

occurs. Continue to hold the control knob for a minimum of 20 seconds

to allow the thermocouple to heat up, if the burner goes out when the

control knob is released, repeat the lighting sequence. d) Turn the control knob in the anti-clockwise direction to the high position

and the gas rate will increase to high rate (6.5 kW) e) Turn the control knob clockwise to the low position and the gas input

will be reduced to the minimum setting (2.2 kW) f) Slightly depress the control knob and turn to the off position, the burner

will now be extinguished.

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.

29 29

3.7 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.

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 pebbles should be made

using suitable long handled tongs and taking care not to damage the

pebbles.

Finally, hand the Installation and Maintenance Instructions and the

Users Instructions over to the customer and explain the operation of the

fire.

Servicing Notes

SECTION 4

MAINTENANCE

Servicing should be carried out annually by a competent person such as a GAS SAFE registered engineer. This is a condition of the Formosa Fires 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 ODS must be changed annually as a condition of the guarantee. 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. All sections apply for both coal, pebble & driftwood fuelbed model variants.

For Diagrams refer to Section 2

4.1 Removing the burner assembly from the fire.

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

4.1.2 Remove the magnetic trim. Remove the fret / ash pan cover or

contemporary trim out of the way and put them in a safe location.

Remove the loose coals, pebbles or driftwood from the fuel bed.

Remove the fuelbed matrix.

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

inlet elbow. Unscrew and remove the two screws which retain the

burner at the base. Lift the burner retaining tabs from the rear of the

firebox & remove the burner assembly from the fire.

4.1.4 To refit the burner assembly. Push the retaining tabs into the rear panel

of the firebox and secure the burner at the base of the control panel

with two screws. Refit the gas supply pipe and carry out a gas

tightness test. Refit the burner heat shield then refit the coals, driftwood

or pebbles referring to section 3 for the correct layout. The trim and ash

pan cover or contemporary trim can now be re-positioned.

4.2 Removing the Piezo Igniter

4.2.1 Remove the burner assembly as in section 4.1

4.2.2 Disconnect the ignition lead from the piezo and unscrew the

retaining nut on the rear of the control panel. Withdraw the piezo from

the front of the control panel. Re-assemble in reverse order and carry

out a gas tightness test.

4.3 Removing the Control Tap from the fire.

4.3.1 Remove the burner assembly as in section 4.1.

4.3.2 Pull the control knob off the control tap spindle.

4.3.3 Loosen and remove the two gas pipe retaining nuts from the control

tap and release the ends of the gas pipes from the control tap body.

Remove the push in thermocouple from the end of the control tap.

4.3.4 Unscrew the control tap locknut from the front of the control panel and

remove the control tap.

4.3.5 To refit a control tap, reassemble in reverse order noting that the control

tap locates with a flat in the control panel. Carry out a gas tightness

test after re-assembly.

4.4 Removing the Thermocouple

4.4.1 Remove the burner assembly as in section 4.1

4.4.2 Remove the push in thermocouple from the end of the control tap and

and remove the thermocouple retaining nut from the mounting bracket

on the burner assembly.

4.4.3 Re-assemble in reverse order and carry out a gas tightness test. PARTS SHORTLIST Replacement of any other parts must be carried out by a competent person such

as a GAS SAFE registered gas installer. The part numbers of the main replaceable parts are as follows, these are available from Formosa Fires contact details shown overpage.

Coal Pack

B-67050

Coal Fuelbed Matrix

B-67040

Pebble Pack

B-68240

Pebble Fuelbed Matrix

B-68230

L/H Fibre Board (Plain)

B-67550

L/H Fibre Board (Brick Back)

B-68170

R/H Fibre Board (Plain)

B-67560

R/H Fibre Board (Brick Back)

B-68160

Lower Fibre Board (Plain)

B-67540

Lower Rear Fibre Board

B-68150

Upp. Rear Fibre Board (Plain)

B-67530

Upper Rear Fibre Board

B-68140

Gas Valve

B-67090

Driftwood Fuelbed Matrix

B-81160

Burner Engine

B-67890

Driftwood Pack

B-81170

Ignition Wire

B-67910

SECTION FIVE - USER INSTRUCTIONS

5.1 Installation Information

Conditions of Installation

It is the law that all gas appliances are installed only by a competent (e.g. GAS SAFE 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 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:- Formosa Fires.

BFM Europe Ltd. Trentham Lakes Stoke on Trent ST4 4TJ

About your Formosa Fires Java

The Formosa Fires Java range of coal, pebble & driftwood fuel-bed gas fires incorporates a unique and highly developed fuel bed which gives the realism of a loose coal or pebble layout combined with realistic flames and glow. The use of durable ceramic material in the construction of the fuel-bed components ensures long and trouble free operation.

When first using the new fire a slight smell may be noticed. This is due to starch used in the manufacture of the soft ceramic coals or pebbles, 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 GAS SAFE 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. These are conditions 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 pebbles, coals or driftwood must be used and only complete and genuine replacement sets must be sourced from BFM Europe

Ltd. The appliance must only be used with the coal, pebble or driftwood set

supplied and must not be used with other coals, pebbles or driftwood. 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 the trim and fret supplied with the fire.

5.2 Operating the Fire

The controls are located behind the ashpan cover which is situated below the fret or contemporary ashpan cover. The controls, comprise a control valve to adjust the gas flow and a push button piezo igniter. To light the fire proceed as follows:-

1) Depress the control knob and turn anti-clockwise to the position

marked ignition rate. Hold in the control knob for a few seconds to allow the gas to reach the burner.

2) Continue to hold-in the control knob and press the igniter button. If the

burner does not light, continue to press the igniter button until ignition occurs. When the pilot has lit, continue to hold the control knob in for a minimum of 20 seconds to allow the thermocouple to heat up, if the burner goes out when the control knob is released, repeat the lighting sequence.

In the unlikely event of a failure of the igniter, the fire can be lit as follows :Depress the control knob and turn anti-clockwise to the position marked ignition rate. Hold in the control knob for a few seconds to allow the gas to reach the burner. Insert the tip of a lit taper in below the fuelbed ceramic matrix above the thermocouple tip. This will light the main burner at low rate.

3) After lighting, turn the control knob in the anti-clockwise direction to the high

position. It is recommended that for most efficient performance the fire is allowed to warm up for a few minutes with the gas control on maximum.

4) The gas control can be turned clockwise from the maximum position to give

the desired heat output.

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.

SPILLAGE MONITORING SYSTEM

This appliance is fitted with a spillage monitoring system which shuts down the fire if the evacuation of combustion products from the fire is affected by a partially or fully blocked flue. If this system operates the fire will go out. If this occurs, leave the fire for at least three minutes then follow the lighting procedure as described in the previous section. In the event of repeated operation a GAS SAFE

registered gas installer must be called to investigate and rectify the cause.

5.3 ASSEMBLING THE FUEL-BED - Coal Fuelbed Model a) Place the fuelbed base centrally on to the fuelbed support and push

fully backwards to the rear face of the fibre boards Make sure that the

fuelbed base is located centrally in the fire box. See figure 26

below. Fig. 26

b) Position the front row of four loose coals along behind the first row of

coals, ensuring that the flame paths as indicated are not interupted.

See figure 27 below.

Fig. 27

c) Fit the remaining three coals onto the ribs in the fuelbed as shown

below, ensuring that the rear flame paths as indicated are not interupted

See figure 28 below.

Fig. 28

The exact position and fit of the coals may be finely adjusted to give the best appearance.

5.4 ASSEMBLING THE FUEL-BED - Pebble Fuelbed Model a) Place the fuelbed base centrally on to the fuelbed support and push

fully backwards to the rear face of the fibre boards Make sure that the

fuelbed base is located centrally in the fire box. See figure 29

below. Fig. 29

b) Position the front row of four large loose pebbles along behind the first

row of pebbles, ensuring that the flame paths as indicated are not

interupted. See figure 30 below. Fig. 30

Beige pebbles to be positioned as indicated

c) Fit the three small pebbles onto the ribs in the fuelbed as

shown below, ensuring that the rear flame paths as indicated are

not interupted. See figure 31 below. Fig. 31

Beige pebbles to be positioned as indicated

The exact position and fit of the pebbles may be finely adjusted to give the best appearance.

Warning : Use only the pebble set supplied with the fire. When replacing the

pebbles remove the old pebbles and discard them. Fit a complete

set of pebbles of the correct type. Do not fit additional pebbles or

any pebbles other than a genuine replacement set.

5.5 ASSEMBLING THE FUEL-BED - Driftwood Fuelbed Model a) Place the fuelbed base centrally on to the fuelbed support and push

fully backwards to the rear face of the fibre boards Make sure that the

fuelbed base is located centrally in the fire box. See figure 32

below. Fig. 32

b) Position the piece of driftwood with the letter “A” stamped onto the

bottom face of it in the position at the left-hand side of the fuelbed

matrix. Ensure the positioning grooves as shown are on the top face of

the piece of driftwood. See figure 33 below. Fig. 33

Driftwood Piece “A” Grooves in top face

as detailed in section b)

c) Position the piece of driftwood with the letter “B” stamped onto the

bottom face of it in the position at the centre of the fuelbed

matrix. Ensure the positioning grooves as shown are on the top face of

the piece of driftwood. See figure 34 below. Fig. 34

Driftwood Piece “B”

Grooves in top face as detailed in sectrion c)

d) Position the piece of driftwood with the letter “C” stamped onto the

bottom face of it in the position at the right-hand side of the fuelbed

matrix. Ensure the positioning grooves as shown are on the top face of

the piece of driftwood. See figure 35 below. Fig. 35

Driftwood Piece “C”

Grooves in top face as detailed in sectrion d)

e) Position the piece of driftwood with the letter “D” stamped onto the

bottom face of it in the position at the right-hand side of the fuelbed

matrix. Ensure this piece of driftwood is located into the groove in the

front right hand side of the fuelbed matrix . See figure 36 below. Fig. 36

Driftwood Piece “D” Locating groove for

driftwood piece “D” in front right hand side of fuelbed matrix

f) Position the piece of driftwood with the letter “E” stamped onto the

bottom face of it in the position at the front centre of the fuelbed

matrix. Ensure this piece of driftwood is located into the groove on

driftwood piece “C” . See figure 37 below. Fig. 37

Driftwood Piece “E” Locating groove for

driftwood piece “E” in centre of driftwood piece “C” and in front section of fuelbed matrix

g) Position the piece of driftwood with the letter “F” stamped onto the

bottom face of it in the across the centre of the driftwood pieces “A”,

“B” & “C”. Ensure this piece of driftwood is located into the groove’s on

the top face of driftwood pieces A, B & C . See figure 38 below. Fig. 38

Driftwood Piece “F” Locating grooves for

driftwood piece “F” in centre of driftwood piece “A”, “B” & “C”

h) Position the piece of driftwood with the letter “G” stamped onto the

bottom face of it in the across the left hand side of the fuelbed matrix,

locating into the grooves on driftwood pieces “A” & “B”. See figure 39

below. Fig. 39

Driftwood Piece “G” Locating grooves for

driftwood piece “G” in top of driftwood piece “A” & “B”

THE FOLLOWING STATEMENT IS APPLICABLE TO ALL FUEL-BED TYPES This appliance uses fuel effect pieces containing Refractory Ceramic Fibres

This appliance does not contain any component manufactured from asbestos or asbestos related products.

IMPORTANT INFORMATION REGARDING FUELBED POSITION ON BOTH COAL, PEBBLE & DRIFTWOOD MODELS.

d) Before continuing with the installation, ensure

that the fuelbed is located behind the locating

tabs as shown below in figure 40, not on top of

the locating tabs as shown in figure 41.

Fig. 40 - Shows correct location of fuelbed

Fuelbed correctly positioned behind locating tabs

Fig. 41 - Shows incorrect location of fuelbed

Fuelbed incorrectly positioned on top of the locating tabs

5.6 Cleaning - WARNING

Before attempting any cleaning operation ensure that the fire has been allowed to fully cool. The Brass fret that was supplied with the fire (dependent upon model chosen) is real brass and therefore will discolour with use and should be cleaned with a proprietory metal polish. The chrome & brass effect trims and chrome effect fret that was supplied with the fire (dependent upon model chosen) should only be cleaned with a clean, damp cloth. The trim 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.

Cleaning the Fuelbed

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 Formosa Fires on the number stated on the rear cover of this book. The coals or pebbles 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 / pebbles. The fuel-bed must be carefully reassembled as stated in section 5.3, 5.4 & 5.5 (dependent upon model chosen), pages 35-44.

5.7 FITTING THE TRIM / CONTEMPORARY FASCIA

a) Fit the outer trim assembly to the firebox with the magnets

provided.

5.8 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.

NOTE : Some models in this range are not supplied with a fret from the

factory, therefore please consult your local retailer for fitting

advice on the type of fret supplied with these models.

USER REPLACEABLE PARTS The only user replaceable parts on this fire are the fuelbed components and

coals or pebbles which may be replaced as described in the above section. Replacement of any other parts must be carried out by a competent person such as a GAS SAFE registered gas installer. The part numbers of the user replaceable parts are as follows, these are available from Formosa Fires who may be contacted at the number on the rear cover of this book.

Coal Pack

B-67050

Coal Fuelbed Matrix

B-67040

Pebble Pack

B-68240

Pebble Fuelbed Matrix

B-68230

Driftwood Fuelbed Matrix

B-81160

Driftwood Pack

B-81170

Due to our policy of continual improvement and development the exact accuracy of descriptions and illustrations cannot be guaranteed.

Part No. B-177180

Issue 1

BFM Europe Ltd.

Trentham Lakes

Stoke-on-Trent

Staffordshire

ST4 4TJ

www.bfm-europe.com

Telephone - General Enquiries : (01782) 339000

Telephone - Service : (0844) 7700169 or (01782) 339008

Formosa Fires Java Installation, Maintenance & User Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual