Stanley Mourne Installation And Operating Instructions Manual
To ensure safety, satisfaction and maximum service, this quality Cooker should be installed by a competent
person. The provision of a Central Heating or Domestic Hot Water facility requires that the hot water system involved
conforms fully to good plumbing practice and established standards.
INSTALLATION AND OPERATING INSTRUCTIONS
To Be Left With End User
Mourne
Solid Fuel Cooker
1
TABLE OF CONTENTS
PAGE NO.
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Mourne Installation Instructions for Plumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Site Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. Pre-Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
9. Chimney / Flues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10. Cooker Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
11. Flue Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
12. Chimney Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13 Hearth Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
14 Down Draughts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15. Use of Existing Flues and Chimneys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16. Ventilation & Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
17. Top & Rear Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
18. Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
19. Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
20. Boiler Output (Central Heating). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21. Gravity Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
22. Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
23. Pipe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
24. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25. Water Circuit Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
26. Care for your Central Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
27. Injector Tee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
28. Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 & 12
29. Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
30. General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
31. Draught Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
32. Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
33. Lighting The Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
34. Operating the Cooker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
35. Fuelling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
36. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
37. Direct Flue Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
38. Oven Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
39. Over Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
40. The Hotplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
41. Main Oven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
42. Overnight Burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
43. Boiler (Summer Conditions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
44. Domestic Boiler Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
45. Riddling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
46. Emptying the Ashpan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
47. Cooker Flue Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
48. Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
49. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
50. Mild Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
51. Ovens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
52. Hot Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
53. CO Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
54. Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
55. Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2
INTRODUCTION
Congratulations on purchasing this fine Irish made Solid Fuel cooker which is built to exacting standards.
Please read the following information before operating this product.
This appliance is hot while in operation and retains its heat for a long period of time after use. Children, aged
or infirm persons should be supervised at all times and should not be allowed to touch the hot working surfaces
while in use or until the appliance has thoroughly cooled.
As manufacturers and suppliers of cooking and heating appliances, we take every possible care to ensure as
reasonably practicable, that these appliances are so designed and constructed as to meet the general safety
requirement when properly used and installed.
The complete installation must be done in accordance with current Standards and Local Codes. It should be
noted that the requirements and these publications may be superseded during the life of this manual.
1. Ash Door
2. Spin Wheel
3. Fire Door
4. Hot Plate
5. Fuelling Cup
6. Chimney Damper
7. Oven Damper
8. Oven Door
9. Cleaning Door
10. Front Plinth
11. Hob
12. Bonnet
13. Plate Rack (optional)
14. Spin Valve
15. Oven Thermometer
Cooker Outputs: At 2.7 kg = 6 lbs coal / hr = 12,300 Btu’s / lb = 7.9 kW / kg
At 2.7 kg = 6 lb timber or peat = 8,600 Btu’s = 5.54 kW / kg
Heat to Water Domestic 10,000 Btu’s = 2.9 kW
Heat to Water 15K Central Heating 15,000 Btu’s = 4.4 kW Burning Coal
Heat to Water 21K Central Heating 21,000 Btu’s = 6.2 kW Burning Coal
Cooker Weight 163Kgs
IMPORTANT NOTICE: Any alteration to this appliance that is not approved in writing by Waterford Stanley will
render the guarantee void.
TECHNICAL DATA
All technical data are taken under laboratory conditions and may vary in use.
Fig.1
13
15
SPECIFICATION
BOILER TAPPINGS:
10K Domestic Boiler:
F = 450 (17
3
/4”) G = 210 (81/4”)
15K Central Heating Boiler:
G = 205 (8”) F = 465 (18
1
/4”)
21K Central Heating Boiler:
F = 475 (18
3/
4”) G = 200 (8”)
IMPORTANT - Control of Substances Harmful to Health:
It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn when
handling materials that could be interpreted as being injurious to health a and safety.
When handling Firebricks, Fire Cement or Fuels, use disposable gloves. Exercise caution and use disposable
masks and gloves when handling glues and sealants. When working with fibre glass, mineral wool, insulation
materials, ceramic blanket/board or kerosene fuel oil, avoid inhalation as it may be harmful. Avoid contact with
skin, eyes, nose and throat. Use disposable protection. Installation should be carried out in a well ventilated
area.
Manufacturers reserve the right to make alterations to design, materials and construction for manufacturing or other reasons subsequent to publication.
* Note:Optional legs are available for this cooker.
See Fig.3.
Note: Dimensions stated are in millimetres and
may be subject to a slight +/- variation.
3
Fig.2
Fig.3
4
INSTALLATION INSTRUCTIONS FOR PLUMBER.
The installation must comply with the following:
The Building Regulations: Part J England & Wales,
Part F Section III Scotland, Part L Northern Ireland.
The Building Regulations: Part J Ireland
Health & Safety at Work Act.
B.S. 8303: Part 1, 2 & 3 - Installation of domestic
heating & cooking appliances using solid mineral
fuels.
B.S. 7593: Treatment of Water in Domestic Hot
Water Systems.
B.S. 7074: Part 1 & 2 - Hot water supply.
I.S. 258: Part 1 & 2 - Domestic Solid Fuel Cookers
with integral boilers.
SITE ASSEMBLY INSTRUCTIONS
1. Remove carton by breaking banding straps.
2. Remove all loose items from Cooker.
3. Carefully lay Cooker on its back.
4. Unwrap Base Assembly Sheet Metal (3
pieces).
5. Bolt Angle End Plates to Cast Iron Cooker
Base using 4 x 5/16” screws provided in
envelope.
6. Fit Front Panel and fix with 4 Self-Tap
Screws, also provided in envelope.
7. Position Assembled Base Unit centrally on
Cooker and tighten all attachment screws.
The hot water available with normal usage of the
range is sufficient for normal domestic
requirements, provided the following conditions of
installation are fulfiled:
(a)The capacity of the storage cylinder does not
exceed 30 gallons.
(b)The cylinder is lagged and is fixed upright.
(c) The cylinder is connected by 1” (25mm) flow and
return pipes with a continual rise and not more
than 8.8 mts. (30 ft.) each in total length. Also if
they exceed 4.5 mts. (15ft.) each in total length
they must be lagged.
(d)Draw off pipes must be ‘dead-leg’ connections,
i.e. there must be no circuit in the draw off: the
user should be advised that the fire should be
continuous burning.
The Flue Connection
Two methods of installation are illustrated in the
diagrams. All joints must be sealed. Square bends
and horizontal runs must not be used. Means of
sweeping the chimney must be provided.
The Boiler
Flow and return connections can be made to run
either L.H. or R.H. from the back of the boiler.
Make good any breakage in the firebox cement
joints between the firebricks and the boiler.
The Hotplate
See that this is firmly bedded to the hob by the
fireproof rope provided.
Lighting Test
Check the installation before leaving the site. Allow
the Range to heat up slowly at first. Check that the
flow pipe from the boiler is assembled in the correct
way. Check the dampers and catches. See that
the user has a copy of the working instructions.
Note: Where a Stanley Range is installed in a
recess which is closed off by a register plate, the
flue pipe should be carried up into the throat of the
chimney to ensure satisfactory results. All flue
joints must be airtight - air should enter the chimney
only by passing through the firebox, or spin valve
item No.3 in the exploded view.
5
1. Lay cooker on it’s back on an old blanket.
2. Attach end plates and front with screws
provided.
3. Stand cooker on it’s base.
4. Move cooker into it’s location and replace all
parts removed.
Parts removal before attaching the base.
Fig.4
Fig.5
Fig.6
Fig.7
6
INSTALLATION
Fig.8
Fig.8a
LOCATION
When choosing a location for this appliance you
must have:
(a) Sufficient room for the installation (see
clearances), a satisfactory flue, and an
adequate air supply for correct
combustion and operation.
(b) Adequate space for maintenance and
air circulation.
(c) Solid floor or base of non-combustible
material which is capable of supporting
the total weight.
PRE-INSTALLATION CHECK
Before installing your new Cooker, check that the
chimney is clean and clear of obstructions.
Cracked brickwork and leaking joints should be
made good and tested accordingly. The chimney
should have a cross sectional area of at least 176
sq. cm (28.28 ins) or an inner diameter of 15 to
23cm (6 to 9 ins). A similar direct air inlet is
required in the room to support combustion.
CHIMNEY/FLUES
The chimney should have a cross sectional area of
at least 176 sq. cm (28 sq. ins) or an inner diameter
of 150mm to 230mm. (6” to 10”). (See fig. 8 & 8a).
Do not connect to a chimney serving another
appliance. Always ensure that the connection is to
a chimney of the same size, never connect to one
of smaller dimensions. Chimneys wholly
constructed of single skin are not recommended
under any circumstances. Due to their inability to
retain heat, such chimneys will inevitably give rise
to smoking, down draught and the formation of
condensation.
The flue must be high enough (more than 4.6m
(15ft.) in any case) to allow the flue gasses to vent
into clear air, away from the turbulence that may be
caused by roof structures, other chimney stacks
etc. The venting position should be 1.0m (3’3”)
above any obstruction within a 7.6m (24’9”) radius,
if down draughts are to be avoided.
COOKER CLEARANCE
The Cooker should not be installed at zero
clearance to combustible materials. The sides
should have a minimum clearance of at least 7.5
cm (3”) from combustible materials unless
otherwise fully insulated.
FLUE PIPES
Where the standard masonry chimney is not
available, a proprietary type of non-combustible or
non-corrosive material 125mm (5”) twin wall, fully
insulated pipe may be used. The pipe must
terminate at a point not lower than the main ridge or
adjacent outside obstructions. With such
installations access to the chimney must be
provided for cleaning purposes.
Horizontal runs more than 150mm (6”) and 90
o
bends numbering more than 2 per installation
should be avoided.
Flues should be vertical wherever possible and
where a bend is necessary, it should not make an
angle of more than 37.5owith the vertical.
IMPORTANT: ALL FLUE CONNECTIONS MUST
BE THOROUGHLY SEALED: BLOCKED
CHIMNEY’S ARE DANGEROUS, USE ONLY
RECOMMENDED FUELS, KEEP CHIMNEYS
AND FLUEWAYS CLEAR.
NOTE: Where the appliance spigot or flue pipes
protrudes into the chimney, care should be taken to
ensure that it does not block the chimney.
DOWN DRAUGHTS
However well designed, constructed and
positioned, the satisfactory performance of the flue
can be adversely affected by down draught caused
by nearby hills, adjacent tall buildings or trees.
These can deflect wind to blow directly down the
flue or create a zone of high pressure over the
terminal.
A suitable anti-down draught terminal or cowl will
usually effectively combat direct down blow but no
cowl is likely to prevent down blow due to a high
pressure zone. Ensure that any cowl used will not
restrict the flue exit.
CHIMNEY CLEANING
Whichever type of flue is chosen, there must be
cleaning access to the whole of the flue system.
The flue of the chimney will need to be cleaned
regularly. How often will depend a lot on how your
Cooker is run, but, to start with, make a point of
inspecting the flue system every one or two weeks.
This period may well be extended as time goes by
if there is little sign of deposits. Some people find
they need to sweep the flue every six to eight
weeks.
HEARTH CONSTRUCTION
Hearth should be strong enough to support total
weight of cooker. When a properly constructed
hearth is not available we recommend that the
Cooker be placed on a slab of foamed concrete 7.5
cm (3”) or a slab of other insulating material. This
hearth must extend at least 40 cm (16”) to the front
and 30 cm (12”) to each side.
A flue pipe should only be used to connect an
appliance to a chimney and should not pass
through any roof space.
Flue pipes may be of any of the following materials:
(a) Cast iron as described in BS 41:1973
(1981)
(b) Mild steel with a wall thickness of at least
3mm.
(c) Stainless steel with a wall thickness of at
least 1mm and as described in BS EN
10095:1999 specification for stainless and
heat resisting plate sheet and strip, for
grade 316, S11, 316 S13, 316 S16, 316
S31, 316 S33, or equivalent Euronorm
88-77 designation.
(d) Vitreous enamelled steel complying with BS
6999: 1989.
STANLEY CAST IRON PIPES ARE HIGHLY
RECOMMENDED FOR INTERIOR USE.
7
Fig.10
Fig.9
A bend should not
make an angle of
more than 37.5
o
with the vertical.
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