Robinson Willey A99003, A99004 Installation And Servicing Instructions

Download

SERVICE & INSTALLATION

Installation and Servicing Instructions

Room Sealed Live Fuel Effect Gas Fire

PRODUCT No. A99003 (BLACK) A99004 (BRONZE)

‘CE MARKED’ FOR USE IN G.B. & I.E.

LEAVE THESE INSTRUCTIONS WITH THE USER

FIRECHARM R.S. LPG

The FIRECHARM R.S. LPG is a room sealed, live fuel effect gas fire with coals. The outer case is available in antique bronze or black finish. The fire can be wall or hearth mounted on a non-combustible wall or hearth, and can be fitted into a suitable fire surround. It can be installed from the inside of a building making it ideal for rooms where access from the outside is difficult, for example multi-storey buildings. A combustible wall kit, G.C. No. 154 759 is available as an optional extra.

Three telescopic flues are available:

Short flue for walls from 75mm to 203mm G.C. No. 994 612 Medium flue for walls from 203mm to 357mm G.C. No. 994 611

Long flue for walls from 357mm to 508mm G.C. No. 994 610 The fire is supplied with the medium flue only. The short and long flues are optional extras. The fire is for use on Propane Gas only (G31 at 37mbar supply pressure). The appliance data badge is positioned on the left hand side of the backplate.

Gas Safety (Installation and Use) Regulations. It is the law that all gas appliances are installed by competent persons in accordance with technical requirements.

The following items relate to this appliance:

1. BS 5871 : Part 1 : 1991

2. BS 5440 : Part 1 : 1990 (Flues)

3. BS 6891 : 1988 (formerly CP331 Part 3)

4. The Building Regulations issued by the Department of Environment and the Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department.

5. Any other relevant British Standard Code of Practice and/or Local Building Regulations.

6. These installation instructions and in accordance with the rules in force.

DESCRIPTION

TECHNICAL REQUIREMENTS

1.0 TECHNICAL DATA

DIMENSIONS Height 633mm Width 646mm Depth 272.5mm Weight 20Kg Max. Heat Input 4.5kW (gross) Min. Heat Input 2.1kW (gross) Max. Heat Output 3.53kW Min. Heat Output 1.55kW Height to Centre Line of Flue 351mm Setting Pressure (Cold) 36.0mbar ± 1mbar (14.4in w.g. ± 0.4in w.g.) Supply Pressure 37.0mbar (14.8in w.g.) Burner - Main Bray Aerated Duplex

- Pilot SIT 0150060

Injector - Upper Bray Cat 100/95

- Lower Bray Cat 100/70

- Pilot SIT No. 20

Ignition Piezo integral with Control Tap Flame Control Concentric TESA 2425 (with flame supervision) Spark Gap 3 to 4 mm Control Knob Settings OFF, PILOT, 1, HIGH, 2, ECON.

This product uses fuel effect pieces containing Refractory Ceramic Fibre (RCF), 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 RCF articles is kept to a minimum, during installation and servicing we recommend cleaning should be carried out in a well-ventilated area or in the open air, by gently brushing with the pieces held away from your face so that you avoid inhaling the dust. We do not recommend the use of a normal domestic vacuum cleaner, which may blow dust back into the air. If a vacuum cleaner is recommended for use by your organisation, you must 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 heavy duty polythene bags, 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 the 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.

2.0 UNPACKING

3.0 SITING GENERAL

The fire is packed in a carton together with the following items (See Fig. 1):-

1. Medium flue assembly and sealing tape.

2. Gasket pack comprising flue and air duct gaskets and sealing gasket.

3. Flue sealing plate.

4. Pack of fittings comprising: 4 Wall fixing screws (2in wood) 810500 4 Wall plugs 820813 1 Spindle washer 810835 3 M4 x 10 Taptite screws (air duct) 810327 2 No. 6 S/T x 10 posi pan 810776

5. Foam seal pack. 822092.

6. A template representing the backplate full size; indicating the positions of the air inlet duct and fixing screw positions.

7. The fuel effect.

Remove the items and keep in a safe place. Lay the fire on its back in a safe place.

The fire must be mounted on the inner face of a suitable external wall of thickness 75mm minimum and 508mm maximum.

(a) HEARTH MOUNTING: If the fire is to be hearth mounted, the hearth must be of non-combustible material at least

13mm thick and measuring at least 670mm wide by 300mm deep with the fire central. Its top surface should preferably

be 50mm above the floor level to discourage placing of rugs or carpets over it.

(b) WALL MOUNTING: The fire may be fitted on a non-combustible wall such that the bottom of the backplate of the fire is

at least 60mm above the finished floor level. NOTE: Soft wall coverings e.g. blown vinyl wallpaper may become discoloured if close to a heating appliance. Please bear this in mind when installing this fire and when redecorating.

cut-out or with a hole 135mm diameter to accept the flue. The material of the surround must be suitable for 100°C application i.e. marked with the suffix ‘100’. The inside of the external wall should be sealed off to prevent draught from the cavity into the room. A foam seal pack is provided for this purpose. Wrap some of the foam seal around the inner air duct so that when the fire is installed, the

foam seal expands to prevent draught into the room.

NOTES;

1. The foam seal starts to expand once the compression tape is removed. Hence the foam seal should be put on only

when the fire is ready to be installed.

2. When fixing the flue length, the wall thickness must be measured from the inner face of the fire surround (Refer to

Section 5.2).

Fig. 1

GASKET

SCREW

INNER

AIR DUCT

INNER

FLUE DUCT

SCREW

TERMINAL GUARD

(OPTIONAL EXTRA)

FOAM SEALING STRIP

SEALING PLATE

FLUE

SEALING TAPE

FLUE

SEALING GASKET

TERMINAL

WALL PLUG

SCREW

3.1 SITING THE FIRE

Outside (Fig. 3): Check that the terminal location complies with the requirements of the table below.

TERMINAL POSITION MINIMUM DISTANCE

A - Directly below an openable window or other opening e.g. air brick 300mm B - Below guters, soil pipes or drain pipes 300mm C - Below eaves 300mm D - Below balconies or car port roof 600mm E - From vertical soil pipes or drain pipes 75mm F - From internal or external corners 600mm G - Above ground, roof or balcony level 300mm H - From a surface facing a terminal 600mm I - From a terminal facing a terminal 600mm J - From an opening in the car port (e.g. door, window) into dwelling 1200mm K - Vertically from a terminal on the same wall 1500mm L - Horizontally from a terminal on the same wall 300mm

B C

A G

Fig. 3

Fig. 2

FOAM SEAL

SEALING PLATE AND ROPE GASKET

Note that in England and Wales the Building Regulations require a terminal guard to be fitted if the terminal is less than 2m (6ft 6in) from the level of any ground, balcony, flat roof or place to which any person has access and which adjoins the wall in which the outlet is situated. A suitable guard assembly is available from Robinson Willey Limited. The part number is

994371. In Scotland, although the Building Standards (Scotland) do not require a terminal guard to be fitted, the fitting of a

guard as detailed above is recommended.

INSIDE:

1. Allow 50mm access at each side of the heater for servicing.

2. Curtains must be 150mm clear at the top of the heater and 50mm at the sides and must not be closeable over the front

of the fire.

3. A wooden or combustible shelf may be fitted over the fire. The minimum height of the underside of the shelf of 125mm

depth must be 130mm . For shelves of greater depth, allow an additional clearance of 15mm for every 25mm additional

shelf depth.

4. A minimum clearance to combustible material of 500mm is required around the heater.

4.0 PREPARATION OF WALL

NOTE: The following instructions relate to normal brick walls. If the wall is wholly or partly of combustible material, a combustible wall kit (optional extra) must be used. Refer to Section 4.4. Check the wall thickness. Three different sizes of flue available for wall thickness up to 508mm as shown below. The medium flue is packed with the heater, the other lengths must be ordered specially.

Short - 75mm to 203mm Medium - 203mm to 357mm Long - 357mm to 508mm

4.1 Place the template against the wall ensuring the top is level. For hearth mounting, ensure that the centre of the flue is

351mm above the hearth. Mark the positions of the flue and four fixing holes and remove the template.

4.2 Cut the hole for the flue making sure that it is straight and level. This can be done with either a 135mm diameter core

drill or hammer and chisel. If neatly drilled no making good is necessary. If not it will be necessary to make good the hole especially at the terminal end where the flue seal will be located and the inside wall face to achieve a good seal.

4.3 Use the template to mark the fixing holes if necessary. Drill the four fixing holes to a minimum depth of 57mm using

6mm diameter masonry drill and insert the plugs.

4.4 COMBUSTIBLE WALLS

1. For installation on walls constructed or comprising combustible materials, reference should be made to the

requirements of BS 5440 and the Building Regulations.

2. Timber Framed Housing: For a timber framed house, the fire can be installed as directed in The Institute of Gas

Engineers Utilization Procedure IGE/UP/7 GAS INSTALLATIONS IN TIMBER FRAME BUILDINGS.

3. The combustible wall kit is suitable for walls in which the combustible part is not more than 195 mm thick measured

from the inside of the building.

4. The combustible wall kit required is ÿ No. 994530, GC No. 154 759. If the whole of the wall is of combustible material,

the outer wall plate must be used, requiring access to the outside of the building.

5. If the screws and the wall plugs supplied are not suitable for a particular application, proprietary cavity wall fixings may

be used.

6. Proceed as detailed in Section 4 for brick walls, EXCEPT for the following points: -

(a) Cut the hole for the flue to a diameter of 178 mm through the plaster board taking care not to damage the Vapour

Control Layer (VCL).

(b) Cut the VCL 10 mm less in diameter than the hole just cut in the plasterboard. This will ensure a seal around the

flue liner.

is constructed of non-combustible material then cut the hole 135 mm diameter making allowances for the shrinkage

†

of the timber frame.

(d) Measure the thickness of the combustible part of the wall and cut the flue liner to this length, cutting off the end

without the fixing brackets. Fit the liner to the sealing plate using the screws provided.

(e) Push the liner through the VCL taking care not to damage the VCL, and ensuring that the liner DOES NOT protrude

into the cavity by more than 10 mm.

(f) If the wall is wholly of combustible material, install the outer wall plate centrally over the hole from the outside as

shown in the diagram below. It is recommended that a silicone sealing compound is applied to the inner face of the wall plate to provide a watertight installation.

(g) Fit the flue, see the Fit Flue section in the Installation Instructions provided with the appliance. NOTE: When

determining the flue length, measure the wall thickness from the face of the outer wall plate.

(h) Slide the rope seal over the flue, until it touches the back of the heater, prior to removing the tape from the flue

foam sealing strip.

(i) Before installing the flue into the wall is necessary to provide a moisture barrier around the flue at the point which

will be in the centre of the cavity. Either of the following methods are acceptable: -

(i) Wrap a wire which will not cause corrosion tightly around the flue. (ii) Form a bead of mastic or silicone around the flue.

† Note: It is not necessary to allow for shrinkage of timber frames in existing buildings where the necessary length of

time has elapsed to allow for any contraction of the timber frame.

5.0 PREPARATION OF FIRE

5.1 Remove Outer Case

(a) Remove the door mask by first lifting upwards to clear the retaining pins and then swinging it out from the fire bottom

first. (b) Pull off the control knob. (c) Remove the four screws, two either side of the fire securing the outer case. (d) Lift the outer case away from the fire and put in a safe place. (e) Remove the glass door by removing the wingnuts on the door surround. Lift off the glass door and put in a safe place.

5.2 Fit Flue

(a) Place the heater face down taking care to protect any soft surface. (b) Fit the flue and air ducts to the back of the heater using the gaskets and screws provided. This operation is made

easier by using the screws to tap the holes before assembly. The four screws for the flue duct are already fitted to the

fire. The flanges of the ducts are marked ‘TOP’ to indicate the way in which the ducts are to be fitted. Note; do not

remove the two middle slotted screws.

NOTE: The flue and air ducts do not need cutting unless the short flue assembly is being fitted. In this case measure

the wall thickness. Then subtract this length from 203mm to give the length ‘B’ shown in Fig. 4B. Cut this length from

the plain ends of both the inner flue and the inner air ducts.

Fig. 4A

‘A’

INNER AIR DUCT

SCREW

TERMINAL

CUT FLUE LENGTH TO WALL

THICKNESS PLUS 140mm (5½in)

134mm

SCREWS

SEALING PLATE

ROPE GASKET

FLUE DUCT

SEALING TAPE

WALL THICKNESS

INCLUDING PLASTER

FOAM

SEALING STRIP

FLUE TERMINAL

125mm DIA.

SEALING TAPE

‘B’

FOR SHORT FLUES CUT THE LENGTH ‘B’ FROM BOTH FLUE AND INNER AIR DUCTS

Fig. 4B

Fig. 4C

Fig 1.

ROPE SEAL

WALL LINER

FLUE

FLUE SEAL

TIMBER FRAME CONSTRUCTION

MOISTURE BARRIER

WALL LINER

OUTER WALL PLATE

FLUE SEAL

FLUE

INNER WALL

PLATE

ROPE SEAL

WHOLLY COMBUSTIBLE CONSTRUCTION

Fig 3B

(c) Adjust the flue length: First measure the wall thickness and add 140mm to give the overall length of flue ‘A’. Fit the terminal assembly to the ducts already fitted to the heater. The top of the assembly is marked ‘TOP’. Set the overall length of the flue to the dimension ‘A’ (Fig. 4A). Drill 2.7mm diameter for the fixing screws but do not fit them yet. Remove the flue terminal. (d) Slide the sealing rope gasket and the sealing plate over the air duct as shown in Fig. 4C. Refit the terminal and secure

it with the screws provided. Seal the joint using the self-adhesive tape provided. (e) Remove the tape from the foam sealing strip on the terminal. Do not remove the tape before the fire is ready to be

installed as the foam strip commences to expand once the tape is removed. The rate of expansion however, is low and

there will be adequate time to install the heater, after which the foam strip will continue to expand and fill the gap

between the flue and the wall. If for any reason the sealing strip has already expanded before the heater is installed, it

can simply be compressed by hand until it is flush with the surface of the flue. (f) Insert the two top wall fixing screws, leaving the plain shank projecting to allow the keyhole top fixing holes to go over

them. Offer the fire with the flue through the wall and hook the keyholes over the screws. Insert the lower wall fixing

screws and secure all four screws. (g) If a terminal guard is required (optional extra) fit it with the kit supplied ensuring that it is concentric with the terminal.

5.3 Connect to Gas Supply (Using rigid or semi rigid tubing incorporating a service cock)

With the outer case removed, the gas inlet pipe is located at the right hand side of the fire. Connect the fire to the gas supply via the union elbow provided. This union elbow should be fitted to the end of the supply pipe and then held in position onto the flare whilst this is engaged. Tighten the flare nut with a spanner. The union elbow has Rp¼ (¼ in B.S.P. internal) thread for supply pipe.

5.4 Test for Gas Soundness (Refer to BS 6891 : 1988)

The gas installation, including the meter, should be inspected and tested for soundness and purged.

5.5 Install Fuel Effect (See Fig. 5)

Remove the coal effect from its pack. The coal effect is a one piece assembly and has a ‘tunnel’ cut out at one end. Fit the coal effect so that this tunnel is over the pilot burner on the right side of the firebox. The coal effect should come to rest on the full length inner front support and also on the two rear coal supports.

5.6 Replace Glass Door

Refit the glass door ensuring all studs protrude through the door evenly. Replace the wingnuts and tighten evenly.

Fig. 5

6.0 COMMISSIONING

6.1 Check the Gas Pressure and F.S.D. Operation

Remove the pressure test point sealing screw located on the gas tap and connect a pressure gauge to the test point. Temporarily fit the control knob. (a) Light the fire. Please refer to the Users Instructions. Turn the control knob to the full on position marked HIGH. (b) Check that the burner pressure is 36mbar ± 1.0mbar (14.4 in w.g. ± 0.4) cold. The fire is designed to give the correct

heat input on Propane Gas at 37mbar (14.8in w.g.) inlet pressure and no adjustment is provided in the fire. Turn off the

fire. Wait 3 minutes then turn the control knob directly to the full on position marked HIGH. The pressure should read

ZERO to confirm the FSD has shut off the gas. Remove the pressure gauge and replace the pressure test screw. Re-

light the fire and test for gas soundness around the sealing screw using a suitable leak detection fluid. (c) Check ignition performance. WARNING: If you want to re-light a hot fire wait three minutes before doing so.

6.2 Refit Outer Case and Remaining Components

Pull off the knob. Replace the outer case by placing it over the fire right hand side first and ensure that the spindle enters the hole in the knob housing before swinging the left side of the case onto the fire. Fit the spindle washer onto the spindle inside the knob housing. Fit four screws two each side to secure the case. Refit the control knob. Refit the door mask. Fit the decorative rail by inserting between the finials and into the holes in same.

6.3 Instruct User (Refer to Users Instructions)

Make sure that the user understands the following:(a) How to light and operate the fire. (b) Demonstrate the removal and replacement of the glass door and the removal and replacement of the ceramics. Advise

on the need to clean these items regularly. (c) Advise that for safe and efficient operation, the fire should be serviced annually by British Gas or a CORGI registered

service agent. (d) When the fire is first lit a slight smell may be noticed but this will quickly clear away with use.

Hand over the Users Instructions.

Important Notes: TURN OFF THE GAS SUPPLY BEFORE COMMENCING ANY SERVICING, ALWAYS TEST FOR GAS SOUNDNESS AFTER SERVICING OR EXCHANGING ANY COMPONENT. It is recommended that the appliance is serviced at least once a year.

1. REMOVE OUTER CASE

(a) Remove the decorative rail from the finials. (b) Remove the door mask by first lifting upwards to clear the retaining pins and then swinging it out from the fire bottom

first. (c) Pull off the control knob. (d) Remove the four screws, two either side of the fire securing the outer case. (e) Lift the outer case away from the fire and put in a safe place. Take care not to lose the spindle washer.

2. GAS TAP ASSEMBLY

Remove outer case (1. above) and after isolating gas supply disconnect the inlet elbow. (a) Removal: Withdraw the spring clip securing the extension spindle assembly to the gas tap spindle and remove the

extension spindle assembly. Undo the union nuts on the tap outlet and remove pilot feed pipe. Disconnect the

thermocouple at the gas tap end. Remove the two screws securing the gas tap bracket to the support bracket on the

fire. Manoeuvre the gas tap complete with inlet pipe away from the fire after disconnecting the inlet pipe clamp. (b) Replacement: Ensure that the new gas tap is in the OFF position by turning the spindle clockwise as far as possible.

Peel off the tape on the pilot outlet and ensure that the pilot filter is retained in the port. Refit the tap using the reverse

procedure to its removal. Refit the spindle assembly. NOTE: With the tap in the OFF position, the flat of the spindle

extension faces towards the right of the fire. Check that the tap functions correctly. Replace the outer case.

(e) Advise the customer that they should read their Users instructions before operating the fire and always follow the

advice in the Section headed "Cleaning your Fire".

PART 2 - SERVICING

3. BURNER ASSEMBLY

Remove the outer case (1. above). Isolate the fire from gas and disconnect the inlet elbow. Remove the glass door (10 wingnuts) and coal bed and put in a safe place. Remove the wingnut on the left side of the firebox, 6 screws holding the burner mounting plate to the right side of the firebox and 2 screws securing the gas tap to its mounting bracket. Disconnect the spindle extension and remove the pipe clamp securing the inlet pipe. Remove the burner, pilot and gas tap assembly by sliding the unit to the right and out of the firebox.

NOTE: If the fire had been previously installed in a fire surround with a restricted access on the right side then it will be necessary to remove the fire from the wall to remove the burner assembly as previously detailed. Alternatively it is possible under these circumstances to remove the control/pipework assembly from the burner first and to withdraw the burner through the front firebox opening. After removing the burner assembly from the fire detach the feed pipes from the gas tap to the injectors at the injector end. By withdrawing the injectors from the burner mounting plate the main burner becomes free and can be exchanged. When fitting the replacement burner transfer the aeration cover from the old burner. Reassemble into the fire following the reverse procedure to dis-assembly.

4. MAIN BURNER INJECTORS

After removing the outer case (1. above) access to the injectors is achieved by first removing the respective injector feed pipe then withdrawing the injector. Only withdraw one injector at a time. The upper injector is size 180 and feeds gas to the centre burner section and the lower injector is size 160 and feeds gas to the outer burner sections.

5. PILOT INJECTOR (SIT No. 20)

(a) Release the tubing nuts at each end of the gas supply tube and remove the tube taking care not to lose the pellet filter

in the pilot outlet of the gas tap. The injector is held captive by the olive in the burner. (b) Replace the injector with a new one. Re-connect the supply tube and tighten the nuts.

6. PILOT FILTER

Proceed as in 5(a) above to remove the gas supply tube. Remove the filter in the pilot outlet of the gas tap. Replace with a new filter and re-assemble.

7. THERMOCOUPLE

(a) Release the tubing nuts at each end of the thermocouple

and remove. (b) Fit a new thermocouple and tighten the nuts.

8. SPARK ELECTRODE

(a) Undo the tubing nut of the thermocouple at the pilot end

and release the thermocouple. (b) Disconnect the spark lead to the pilot. (c) Undo the tubing nut of the electrode and remove the electrode. (d) Replace with a new electrode and re-assemble in the reverse

manner. Do not over tighten the nut.

9. PILOT BURNER

Release pilot feed tube, thermocouple and spark electrode as detailed in 5, 7 and 8 above. Remove 4 screws securing the pilot burner to the support plate and withdraw the pilot burner. Transfer gasket from the old pilot to the new pilot and fit the new pilot. Re-assemble the remaining components in the reverse manner to removal.

15mm

13mm

SHORT LIST OF PARTS

991323 Issue 3

ROBINSON WILLEY LIMITED

Mill Lane, Old Swan, Liverpool L13 4AJ

Telephone: 0151-228 9111 Fax: 0151-228 6661

MAKERS NUMBER DESCRIPTION

991328 Coal Bed

991967 Control Knob

822197 Gas Tap

820363 Spark Electrode

822131 Pilot Filter

822183 Thermocouple

991635 Door Assembly

991976 Spark Lead

Robinson Willey A99003, A99004 Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual