Royal Consumer Gas Fire User Manual

0102 095 50023

CLASS 2 – FLAME SYSTEM 3

USERS (Pages 2-3)/ INSTALLATION (Pages 4-9)

AND SERVICING INSTRUCTIONS

THIS CAT I

ON NATURAL GAS G20 AT A SUPPLY

PRESSURE OF 20 mbar IN GB and IE

HAND THESE INSTRUCTIONS TO THE USER

2H APPLIANCE IS FOR USE

USERS INSTRUCTIONS

Description

This Royal Cozy Fires Decorative Fuel Effect gas fire has been developed to give a realistic coal burning appearance with
the instant control and convenience of gas. The fire has been constructed to enable it to be installed into most applications
(using the optional spacer frame) where the warmth and comfort of an open fire with high radiant heat is required. This
appliance is intended for decorative purposes and the coal bed uses ceramic simulated (coals) to give a realistic
appearance and to allow secondary air to be entrained into the bed to ensure clean combustion. An aerated single ported
steel burner is used running parallel across the front of the fire. A combined gas control and piezo igniter with a variable
high to low setting is used, this is fitted with a Flame Supervision Device (FSD). This is to ensure that should the pilot
flame be extinguished for any reason, (including turning off the appliance) the gas supply to the burner is cut off until a
full lighting sequence is repeated. The Piezo igniter is used to ignite an Oxy-Pilot sensor (ODS) which will cause the
appliance to (shut off) in the event of continued spillage occurring under hazardous or blocked flue conditions. The fire
bed consists of ceramic fibre components and coals all of that are removable for cleaning purposes when required. It is
important when relaying the coal-bed and coals to follow the instructions correctly.

This appliance is suitable for installations into the following flues:

7" minimum diameter flues (CLASS 1)
5" minimum diameter flues (CLASS 2),

Pre-cast flues to BS 1289 Pt 1 1986 (when spacer frame is fitted).
The installations must always be used in conjunction with a suitable hearth and surround (refer to page 5 for further
details).

Important Notes

A hearth must always be provided to project forwards of the brass trim a minimum of 300mm and a minimum of 150mm
either side of the fire opening. The hearth must be a minimum thickness of 12mm with a perimeter height of 50mm to
deter combustible materials, carpets etc., being placed on the hearth. The area under the firebox must have a minimum
non-combustible thickness of 25mm.

The appliance is fitted with an ODS, a spillage monitoring system which operates if the evacuation of products is
interrupted (i.e. blocked or incorrect flueing). If the gas fire repeatedly ‘goes out’ it may indicate a problem and the
installer or specialist should be informed before further use.

Areas of this appliance will become hot after prolonged running and it is recommended that for the protection of the very
young, elderly and infirm a fireguard conforming to BS 6539 or BS 6778 be used.

Care should be taken to prevent any damage being caused to surrounding soft furnishings or decor e.g. many embossed
vinyl wall coverings may become discoloured if located close to the appliance. Clearances required for combustible
shelves are shown in page 3.

Care should be taken to ensure that when the appliance is installed into a Pre-cast flue, the chimneybreast is lined to
prevent the plaster etc. cracking through excessive temperatures.

In most installations a back panel will be required, this will also need a minimum fire resistance rating of Class O (100
C).

This product uses fuel effect pieces, gaskets and insulation material 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.

O

A range of fronts and frets are available for use with this appliance, these have perforated frets to allow air to be drawn
into the coal bed for combustion and over the controls for cooling purposes. If other fronts and frets are to be used they
must have a minimum open area in the fret of 20sq cms and 60sq cms in the front. See Fig. 11.

The chimney or flue (unless new) must be swept before installation. It should be checked annually for satisfactory
clearance of products and that there is no excessive build up of soot.

TO LIGHT THE APPLIANCE

1. Remove the Fret (Controls cover), to gain access to the controls.

2. Press and turn the gas control anti-clockwise, keep the control fully depressed. The igniter will operate and the pilot will

light, if not repeat the operation.

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3. 0nce a pilot-flame has been established; keep the control depressed for a further 20 seconds. Release the gas control and

check that the pilot remains lit.

4. Depress the gas control slightly and turn anti-clockwise until the indicator mark is aligned with the letters HIGH. The

burner will cross light from the pilot.

5. Depress the gas control slightly and turn anti-clockwise until the indictor mark is aligned with the letters LOW. The

burner will now be at minimum rate.

6. To turn ‘off ‘ the appl iance, re turn the contro l to the ‘OFF’ position.

7. If for any reason the fire cuts out, return the control knob to the `OFF’ position and wait 3 minutes before re-lighting.

8. In the event of failure of the igniter the fire may be lit by placing a lighted taper or match at the pilot position at the

same time depressing the gas control in the IGN position.

Removal of Debris or Soot Deposits
Debris from any source or any soot formed shall require removal. Allow the appliance to cool sufficiently before

removing all of the coals and firebed components for cleaning purposes. Once all the ceramics are removed from the
firebed check that no debris is located in the burner slots. If any debris is present it may easily be removed by using a
small piece of thin cardboard to ease out any foreign matter. Be sure to remove the cardboard after use. Should any soot
accumulation become excessive, the fuel effect pieces should be removed from the fire for cleaning. 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

Laying the Coal Bed

. Any sooty deposit on the thermocouple probe can be cleaned off using a non-fluffy cloth.

The coal support shelf is positioned on the fibre support metalwork, ensure that the shelf sits against the two stops which are
to prevent the shelf sitting on the burner outlet. Place the simulated coal front in position as shown in Fig.6, three tabs are
provided to locate. The one-piece coal support shelf is constructed to allow three levels of coal support; these three levels are
shown in Fig 7, the plan view of the bed.
.

Coal Layout (See Figs 6 - 9) (6 Large and 12 small)

First Layer.
shelf. Ensure the gap indicated is left clear to v iew the pilot flame.

Place 3 large coals on the middle level of the coal support shelf as show n.
Second Layer. Place 4 small coals in position to fill gaps betw een the coa ls on the lower and middle level of the coal support

shelf
Place 2 small coals in position to straddle the 3 large coals on the middle level and upper level of the co al suppor t shelf..
NOTE: Additional coals must not be used. If any of the coals or coal bed become damaged, lost or broken, replacements

must be obtained (part numbers listed in short spares list) before th e appliance i s used.

VENTILATION

Additional purpose built ventilation is not required for this appliance in GB only, for IE ventilation is required with a
minimal cross section area of 100sq cms, it should be checked regularly to ensure that it is free obstruction

Clearance to Side (Timber Surrounds etc.)

Position 3 large coals and 6 small coals between the front simulated coal and the lower level of the coal support

Minimum clearance required to any combustible material to the side of the appliance must be 150mm

Clearance to Shelves

Minimum clearance to the underside of a 150mm deep combustible shelf from the hearth must be 790mm. Add 12.5mm
to this clearance for every 25mm increase in depth of shelf.

The list of coal part numbers that the user can replace is at the back of this document.

This appliance is intended for decorative purposes.

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INSTALLATION INSTRUCTIONS

THE FOLLOWING SECTION LISTS THE INSTALLATION REQUIREMENTS AND REGULATIONS

A competent person in accordance with the current Gas Safety (Installation and Use) Regulations or the rules in force and
in accordance with the manufacturer’s instructions must install the appliance; failure to do so could lead to prosecution.

The following are the relevant Codes of Practice and British Standards.
The Building Regulations issued by the Department of the Environment. The Building Standards (Scotland)

(Consolidation) Regulations issued by the Scottish Development Department.

BS 8303 Pt 2 1994 BS 5440 Pt. 1 1990 & Pt. 2 1989

BS 1251 1987 BS 5871 Pt. 2 1991 & Pt. 3 1991

BS 6891 1988 BS 6461 Pt. 1 1984

BS 715 1993 BS 1289 Pt. 1 1986

BS 7566 Pts. 1-4 1992

Technical Data

Overall height of fire with spacer = 612mm

Overall height of fire without spacer = 605mm

Minimum height of opening required = 540mm

Maximum height of opening with spacer = 590mm

Maximum width of opening required = 405mm

Maximum width of opening with spacer = 470mm

Forward projection from opening = 60mm

(without front and fret)

Forward projection from opening with = 105mm

spacer (without front and fret)

Depth behind opening without spacer = 190mm

Depth behind opening with spacer = 145mm

(See page 18 for diagram)

TYPE OF GAS G20 only
Supply Pressure 20 mbar +/- 1 mbar (Cold)

GAS INPUTS
Max 6.6 kW (22520 Btu/h)
Min 3.6 kW (12300 Btu/h)
Pilot 0.26 kW (890 Btu/h)

Main Injector Type
Stereomatic 046/19/196/74M
Gas valve Concentric TESA 3058/S

Pilot OP Oxy-Pilot NG 9022
GAS CONNECTION 8MM OD Tube
WEIGHT

12.5 kg (without front and fret)

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Installing the Appliance

Check that the chimney and flue structure are sound and conform to the following flue requirements.
a) A conventional brick or stone chimney with a minimum effective cross sectional dimension of 225 x 225mm. A lined

flue with a minimum diameter of 175mm having a chairbrick and throat forming lintel conforming to BS 1251 or a
builders opening (constructed of non-combustible material) measuring 540mm high x 400mm wide with a sufficient
depth for debris collection. If a chairbrick is fitted, a minimum depth requirement for the fire with the spacer frame fitted
is shown in Fig 1, if a spacer frame is not used, the chairbrick will have to be removed.

b) A twin walled metal flue box manufactured to BS 715 with a twin walled 125mm diameter flue and a minimum
effective height of 5 metres. See page 12.

c) A pre-cast flue conforming to the requirements of BS 1289 Pt. 1 1986 and BS 1289 l975 including properly constructed
pre-cast flues with a cross sectional area of 13000sq mm.

Important

Dampers, register plates or incorrect flue terminals, must not restrict the above listed flues. The flue must only service a
single appliance and not have any branches or traps that may impede the natural draught. Any flue damper plate or
restrictor shall be removed or fixed in the fully opened position.

The front and base of the fire opening must be flat and square to ensure a good seal with the appliance; this is to ensure
that there is no reduction in draught through the fire that may cause spillage to occur.

Contents Check List

Fire Box Assembly c/w Burner Assembly

Simulated Coal Front
Coal Support Shelf

Coal Pack including: - 6 Large Coals

12 Small Coals

Fitting Kit: - 7" (175mm.) x 5" (125mm) Spigot Restrictor

Screws & Wall Plugs, Sealing Strip and Fixing Straps
and Self/tap Screws
Users & Installation and Servicing Instructions

Spacer Frame Kit: (Optional) Spacer Frame Assembly

Fire Surround and Opening Requirements

7in Diameter Flue, Chairbrick and Builders opening (Class 1). See Fig 1.

5in Diameter Flue and Metal Flue Box (Class 2). See Fig 2.

Pre-cast Flues. See Fig 3.

VENTILATION

Additional purpose built ventilation is not required for this appliance in GB only, for IE ventilation is required with a
minimal cross section area of 100sq cms, it should be checked regularly to ensure that it is free obstruction

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Installation using a 5” Diameter Metal Flue Box

Important: The spigot restrictor marked ’B’ must be fitted. See page 7.
When the metal flue box is to be built-in as a false chimneybreast using the timber studwork with plasterboard facing, the

metal flue box should be enveloped with insulation material such as Rockwool or similar to prevent a build-up of heat
within the structure. Either an air gap of 75mm should be maintained between any combustible materials and any part of
the metal flue box or a minimum of 25mm of insulation material between the metal flue box and the combustible
material.

It is important that both the back panel and the appliance are sealed to the metal flue box to prevent any leakage of flue
products or reduction in the flue draught.

Installation of the Appliance

Check that the chimney conforms to the required specifications as previously stated. Examine the condition and carry out
any remedial work necessary, if the flue has been used for solid fuel it should be swept and a smoke test carried out to
check that satisfactory smoke clearance has been established. If all the smoke is not drawn into the flue, pre-heat the flue
with a blowtorch or similar and re-check. If there is any uncertainty examine for the cause and if necessary seek expert
advice.

GAS SUPPLY
BEFORE COMMENCING WORK, TURN OFF ANY APPLIANCES THAT ARE FED BY THE METER AND

ISOLATE THE GAS SUPPLY BY TURNING OFF AT THE METER

The gas connection to this appliance is made with 8mm o/d rigid or semi rigid tube to a combined pressure test/ restrictor
elbow situated on the R/H side of the burner. Provision is made i.e. knockout blanks for entry into the box in both L & R
hand rear corners and at the L & R hand sides. Any pipe used under the tray must be in rigid tube such as bundy, A
suitable piece of bundy is included in the fitting kit to assist the installer..

Where a concealed gas supply is used, the installer is reminded of the requirements of BS 6891 1988 dealing with
enclosed pipes. The Standard requires that when a gas pipe is fed through a wall, the pipe should be enclosed in a tight
sleeve to protect against failure caused by movement. It shall be constructed to prevent passage of gas either between the
pipe and sleeve or sleeve and wall.

Where a gas supply pipe enters the box in any of the positions stated, the hole around the pipe should be sealed with a
silicone sealant or similar to prevent Ingress of air into the flue. Permanent sealant e.g. fire cement etc should not be used
as these would prevent removal of the firebox.

Dismantling the fire Pr ior to Installing

It will be necessary to dismantle the burner from the firebox before installing the box in the opening.
To remove the burner from the box unscrew the two screws at the base of the fascia panel and lift the assembly

approximately 200mm at the front to clear the fixing flange. When refitting observe that the two feet at the rear of the
assembly locate under the two lugs form ed in the base of the box assem bly.

If the installation has either a 5in (125mm.) or 7in (175mm) flue if will be necessary to select the appropriate restrictor,
(See page 7). To insert the correct restrictor plate remove the centre screw securing the fibre retaining strip in position and
slacken off the two outer screws to allow the two slots in the restrictor plate to slide behind the two screw heads and
replace the centre screw and tighten the outer screws.

Important
THE RESTRICTOR PLATE 'A' AND 'B' (marked 1 dimple/2 dimples) MUST NOT BE USED WITH PRE-CAST

FLUES.

The restrictor ‘A’ marked with 1 dimple is for use with 7in (175mm) diameter flues and the restrictor ‘B’ marked with 2
dimples is for use with 5in (125mm) diameter flues.

The appliance is supplied without any Flue Restrictor fitted in position i.e. suitable for pre-cast flues.
The correct fitting of the restrictor plate is carried out prior to installation. See Fig 4. Two self-tap screws are provided to

hold the restrictor in position. The single dimple is uppermost for the ‘A’ position and the double dimple uppermost for
the ‘B’ position.

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