The Collection Carmello HE DCMLxxRN2, Carmello HE DCMLxxRP2 Installation, Maintenance & User Instructions
Carmello HE
HIGH EFFICIENCY BALANCED FLUE
INSET ROOM HEATER
Installation, Maintenance & User Instructions
Hand these instructions to the user
Model No’s DCML**RN2 is for use on Natural Gas (G20) at a supply pressure
of 20 mbar in G.B. / I.E.
Model No’s DCML**RP2 is for use on Propane Gas (G31) at a supply
pressure of 37 mbar in G.B. / I.E.
** Denotes trim & colour variant
CONTENTS
PAGE
S
ection 1 Information and Requirements
1.0 Appliance information 3
1.1 Conditions of installation 4
1
.2 Flue terminal position 5
1.3 Shelf position 6
1.4 Hearths 6
1.5 Efficiency Declaration 6
Section 2 Installation of Fire
2.1 Unpacking the combustion chamber 7
2.2 Preparing the combustion chamber opening (In studded wall) 8
2.3 Preparing the combustion chamber opening (In chimney breast) 9-10
2.4 Securing the fire to the opening 11
2.5 Installation of the gas supply 12
2.6 Specifying the flue system & components 13
2.7 Balanced flue in horizontal flue configuration 14-15
2.8 Balanced flue in vertical flue configuration (flat roof) 17
2.9 Balanced flue in vertical flue configuration (pitched roof) 18
2.10 Balanced flue utilising existing chimney 19-20
2.11 Making the electrical connection 21
2.12 Removing the glass panel 22-23
2.13 Removing the burner assembly 24-26
2.14 Finishing the product aperture / fitting the plaster frame 27
Section 3 Assembling Fuel Bed and Commissioning
3.1 Fitting the fuel bed logset 28-33
3.2 Fitting the fuel bed pebbles set 34
3.3 Lighting / operating the appliance 35-40
3.4 Removal / re-fitting of the restrictor baffle 41
Section 4 Maintenance
4.1 Removal of the burner assembly 42
4.2 Removal of the gas control valve 42-43
4.3 Removal of the ultrasonic reciever 43
4.4 Removal of the pilot assembly 43
4.5 Removal / Replacement of the convection fan / thermal switch 43
4.6 Removal / Replacement of the handset battery 44
4.7 Wiring diagram 45
Section 5 User Instructions
5.1 Installation Information / about the Carmello HE BF 46-47
5.2 Important safety information 47
5.3 Lighting the appliance / user controls 48-52
5.4 Cleaning& removing / replacing the glass panel 54-55
5.5 Removal & re-fitting the fuel-bed logset 56-61
5.6 Removal & re-fitting the pebble fuel-bed pebble set 62
Model numbers DCML**RN2 & DCML**RP2 are manufactured by:-
BFM Europe Ltd. Trentham Lakes, Stoke-on-Trent, Staffordshire, ST4 4TJ
2
SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APPLIANCE INFORMATION
Main injector : (1 off) Stereomatic – size 2.55 (NG)
Stereomatic – size 1.52 (LPG)
Pilot Type : G20 (NG) - Polidoro G27.2
G31 (LPG) - Polidoro G24.1
Max. Gross Heat Input : 9.5kW (G20) 7.8kW (G31)
Min. Gross Heat Input : 5.5kW (G20) 5.5kW (G31)
Gas Rate : (High) NG = 0.878 m3/hr, LPG = 0.282 m3/hr
Gas Rate : (Low) NG = 0.508 m3/hr, LPG = 0.207m3/hr
Cold Inlet Pressure : G20 - 20.0+/-1.0 mbar (8.0 +/- 0.4 in w.g.)
G31 - 37.0+/-1.0 mbar (14.8 +/- 0.4 in w.g.)
Ignition : Via remote handset, integral to gas valve
Electrode Spark Gap : 4.0mm
Packed Weight Combustion Chamber : 76.0 kg (Pack 1 of 2)
Packed Weight Flue Terminal Pack : 16.0 kg (Pack 2 of 2)
Supply Voltage : 230V a.c.
Supply Frequency : 50Hz
Supply Fuse : 3 Amp to BS 1362
Electrical Supply Required 230v AC, 50Hz
IP Rating IPX0
Fig. 1 Fig. 2
Top View of Combustion Side View of Combustion
Chamber Chamber
3
1227mm
1150mm
370 mm
530mm
580mm
370mm
172mm
101mm
117mm
25mm
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 1 Installation of Gas Fires
2. B.S. 6891 Installation of Gas Pipework
3. B.S. 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. I.S 813 : 1996 Domestic Gas Installation, issued by the National Standards
Authority of Ireland.
4
1.2 FLUE TERMINAL POSITION
The minimum acceptable dimensions from the flue terminal to obstructions
and ventilation openings are shown below and listed in the table
It is important that the position of the flue allows the free passage of air
across it at all times. The minimum acceptable space from the flue terminal
to obstructions and ventilation openings are specified below (figure 3)
Fig. 3
DIMENSION TERMINAL POSITION MINIMUM DIMENSION
A Directly below an opening, air brick, 300mm (12in)
opening window
B Above an opening, air brick, 300mm (12in)
opening window
C Horizontally to an opening, air brick,
opening window etc.
D Below gutters, soil pipes or drain pipes 300mm (12in)
E Below eaves 300mm (12in)
F Below balconies or car port roof 600mm (12in)
G From a vertical drain pipe or soil pipe 300mm (12in)
H From an internal or external corner 600mm (24in)
I Above ground roof or balcony level 300mm (12in)
J From a surface facing the terminal 600mm (24in)
K From a terminal facing the terminal 600mm (24in)
L From an opening in the car port 1200m (48in)
M Vertically from a terminal on the same wall 1500mm(59in)
N Horizontally from a terminal on the 300mm (12in)
same Wall
O NOT APPLICABLE N/A
P NOT APPLICABLE N/A
Q NOT APPLICABLE N/A
5
1.3 SHELF POSITION
The fire may be fitted below a combustible shelf providing there is a minimum
distance of 300mm 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.
1.4 HEARTHS
This appliance does not require the fitting of a hearth that projects in front of it
when installed into a recess in either an existing chimney breast or a studded wall,
providing the appliance is installed a minimum of 225mm above the floor level.
The appliance must however stand on a non-combustible base within the opening
that is a minimum thickness of 12mm
1.5 APPLIANCE EFFICIENCY DECLARATION
The efficiency of this appliance has been measured as specified in
BS EN 613 : 2001 and the result is 68% on both Natural Gas & LPG. 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 the British
Standards Institute (BSI). The efficiency value may be used in the UK
Government’s Standard Assessment Procedure (SAP) for energy rating of
dwellings.
6
SECTION 2
INSTALLATION OF FIRE
2.1 UNPACKING THE COMBUSTION CHAMBER
Carefully lift the combustion chamber out of the carton. Remove the loose item
packaging carefully from the pack. Check the contents as listed :-
DO NOT UNDER ANY CIRCUMSTANCES USE THIS APPLIANCE IF THE
GLASS PANEL IS BROKEN OR NOT SECURELY FIXED TO THE FIREBOX.
Packing Check List
Pack 1 of 2 - Combustion Chamber Pack
1 off Combustion Chamber & Glass Assembly
1 off Boxed ceramic fuel-bed set (packed inside combustion chamber)
1 off Installation instruction / user manual
1 off Plastering frame
1 off Thermostatic remote handset
1 off Loose items pack – containing :- 4 off No. 12 x 40mm screws, 4 off
rawlplugs, 3 off restrictor baffles, 2 off restrictor baffle retaining screws,
1 off glass clamp, 1 off grommet, 3 off AAA batteries, 1 off remote
handset wall bracket
Pack 2 of 2 - Horizontal Balanced Flue System Pack
1 off Adaptor 1 off 0.5m length of flue
1 off 90 degree elbow 1 off Horizontal wall terminal
2 off Locking bands 1 off Protection band
or
Pack 2 of 2 - Chimney Conversion Kit
1 off Adaptor 2 off 250mm length of flue
1 off Renovation kit 1 off Vertical terminal
2 off Locking band
or
Pack 2 of 2 - Vertical Flue Kit
1 off Adaptor 1 off Vertical terminal
In addition, all flue lengths, roof flashing, clamps and accessories as required by
the individual flue system design should be purchased as required from the
manufacturer, contact details shown on the bottom of page 13.
7
2.2 PREPARATION OF THE COMBUSTION CHAMBER OPENING
(INTO STUDDED WALL)
All combustible parts of the studwork must be set at the distances as shown below
in figure 4 & 5.
8
Minimum 50mm at sides
Minimum 50mm at rear
Combustion Chamber
Dimension “A”
Opening Width = 1170mm
Dim “A”
Dim “B”
Dimension “B”
Opening Height = 555mm
Dim “C”
Dimension “C”
Minimum Depth 420mm
Fig. 4
Fig. 5
MINIMUM HEIGHT FROM
FLOOR LEVEL TO
BOTTOM OF OPENING IS
225MM
PLEASE NOTE : For the front face of the studwork
a non combustible board such as “Versa Tecbor”
should be used in a double 12mm thickness.
“Versa Tecbor” board is available from Euroform
Products Ltd, Tel : (01925) 860999,
www.euroform.co.uk
Studwork
2.3 PREPARATION OF THE COMBUSTION CHAMBER OPENING
(INTO EXISTING CHIMNEY BREAST)
An opening should be constructed to the following dimensions in the existing
chimney breast. See figure 6 below.
Fig. 6
PLEASE NOTE : The opening size as detailed above will require
reducing in size to the product aperture and finishing in a high
temperature plaster finish as detailed in section 2.14
NOTE : Please ensure that suitable cut outs in the sides and front face of the
chimney breast are implemented for fixing of the flue pipe, and for future
servicing.
9
Width = 1170mm
Height = 545mm
Depth = 380mm
L
intle must
p
roject 150mm
either side of the
opening if
cutting into an
existing chimney
breast
Fig. 7
The opening needs to be sufficient to accomodate the combustion chamber. To
support the wall above the opening, a suitable lintel must be inserted across the
top of the opening. The lintel could be either pre-cast concrete or steel - Catnic
CN52 or CN 46 could be used, depending upon the inner wall thickness. Before
proceeding with the installation of the fire, an assessment of the area immediately
above the fire is required, see figure 7 above. If there is no existing openings
within either triangle, proceed with forming the opening. However, if opening or
beams occur within either triangle, then you should seek specialist advice from a
structural engineer or consider relocating the proposed position of the firebox.
NOTE
: It is recommended that suitable cut outs in the sides and front face
of the chimney breast are implemented for fixing of the flue pipe, and for
future servicing.
The appliance must be sited on a non combustible base. The appliance can be
placed onto a combustible material providing a heatproof board such as superlux
of minimum 12mm thickness or similar is placed under it.
IMPORTANT : Any air supply to the fireplace opening must be sealed off
10
400mm interactive area
6
00mm load triangle
T
he Interactive Zone Openings, beams or joists within
this area need to be assessed.
L
oad triangle - No beam or
opening permissible within this
area
Lintel
e.g. 750mm x 75mm
Proposed Opening in
Chimney Breast
11
2.4 SECURING THE COMBUSTION CHAMBER TO THE OPENING
2.4.1 The combustion chamber must be secured to the opening via the four
off screw and rawlplugs provided. Figure 8 below shows the hole
centres in the mounting flanges of the combustion chamber.
Fig. 8
2.4.2 DO NOT SECURE THE COMBUSTION CHAMBER INTO THE
OPENING AT THIS POINT AS ACCESS WILL STILL BE REQUIRED
TO RUN THE GAS SUPPLY PIPEWORK AS DETAILED IN SECTION
2.5
Fig. 9
350mm CRS
1206mm CRS
4 holes in combustion
chamber mounting flange
for securing to the opening
80mm
150mm
1206mm CRS
350 CRS
2.5 INSTALLATION OF THE GAS SUPPLY (INTO STUDDED WALL OR
EXISTING CHIMNEY BREAST)
Before installing the combustion chamber, decide from which side or if a rear
connection to the gas supply is required. Plan the pipe run to enter from the rear
or below the firebox from the left, right or rear and connect to the inlet elbow. See
figure 10, 11 & 12 below. The gas connection is located at the front right hand
side of the fire. Note : Before breaking into the gas supply a gas tightness
test should be carried out to establish that the existing pipework is sound.
12
Combustion Chamber
Gas Supply entering from L/H/S
Combustion Chamber
Gas Supply entering from Rear of Combustion Chamber
Outer
Cavity Wall or
rear face of
studwork
Ensure if bringing gas
supply through side or rear
of a chimney breast that the
pipe is sleeved and sealed
with a suitable flexible, non
setting compound
Fig. 10
Fig. 11
Combustion Chamber
Fig. 12
Gas Supply entering from R/H/S
2.6 SPECIFYING THE FLUE SYSTEM & ASSOCIATED COMPONENTS
This product comes with the optional of 3 methods of flueing :-
Decide upon the method of flue that is most suitable for the property in which you
are installing the product, from the following options :-
2.6.1 Balanced Flue in Horizontal Configuration
This flueing method uses a 0.5 metre vertical pipe starter pipe section, then
utilises a 90 degree elbow and a terminal section to provide a horizontal pipe from
324mm (minimum) up to 469mm (maximum). Additional flue duct can then be
purchased to allow installation up to a maximum wall thickness of 1554mm. The
flue can be installed to terminate directly out the wall behind the appliance or at
the L/H side or R/H side by rotating the elbow section. If the terminal is fitted
below 2m from ground level, a terminal guard must be fitted in England & Wales.
BFM Europe supply a suitable guard in the Horizontal Flue Kit. See section 2.7
2.6.2 Balanced Flue in Vertical Configuration
This flueing method utilses a rigid interlocking balanced flue duct to enable a
vertical balanced flue system to be used. All components required are supplied
within the flue kit with the exception of the lengths of co-axial pipe which is
dependent upon the individual installation. This method is most suited when a
false chimney breast is being constructed due to no chimney / insufficient depth
and an outside wall is not available. See section 2.8 / 2.9
2.6.3 Balanced Flue Utilising Existing Chimney
This flueing method uses a 4” / 100mm flexible flue liner fitted into an existing
chimney breast, with a specially designed flue termination fitted to the top of the
chimney. All components required are supplied within the flue kit with the
exception of the 4” / 100mm flexible flue liner, which is dependent upon the
individual installation. Please ensure any flexible flue liner used is rated to T400.
This method is most suited when an existing chimney breast is available that is in
good condition and has sufficient depth to accept the product. See section 2.10
If you require to purchase any additional flue components, please contact the UK
distributor for Metaloterm products, contact details as below :-
H Docherty Ltd
Unit 15 &16 Colthrop Business Park
Colthrop Lane
Thatcham
Berkshire
RG19 4NB
Tel : 0845 6031715 Fax : 01635 201737
13
2.7 BALANCED FLUE IN HORIZONTAL CONFIGURATION
2.7.1 Horizontal balanced flue configuration and components identified as
shown below in figure 13.
Fig. 13
PLEASE NOTE : THE FLUE TERMINAL SHOULD BE FITTED
WITH THE WELDED JOIN LINE AT THE BOTTOM, FACING
THE GROUND
14
Height to flue centre = 1305mm
Combustion
Chamber
Adaptor
324mm Min
469mm Max
1554mm Max
This is the standard flue duct
supplied. 1 metre length of
metaloterm flue can be added if
necessary to acheive
maximum flue length of 1554mm
1 metre length of metalotherm
flue duct
2.7 BALANCED FLUE IN HORIZONTAL CONFIGURATION (CONTINUED)
2.7.2 Mark the position of the centre of the flue on the inner wall. (See figure
13 on previous page for position).
2.7.3 Cut hole for outer flue pipe. There are two possible methods to achieve
this, either core drill or via hammer and chisel.
2.7.4 To core drill, proceed as follows :-
2.7.5 Drill a pilot hole through the wall, in position as specified in figure 13 on
previous page.
2.7.6 Using a 6” core drill, drill the flue hole.
2.7.7 To Hammer and chisel, proceed as follows :-
2.7.8 Mark the position of the centre of the flue pipe as specified in figure 13.
2.7.9 Mark the position of the hole around this point.
2.7.10 Chisel out the area as marked on the wall.
2.7.11 We then recommend that a cardboard cylinder is placed around the flue
pipe and inserted in the chiselled out hole whilst making good. A wall
plate is provided on the flue duct to seal the terminal around the
flue pipe opening and make good.
Please ensure all joints are taped with suitable high temperature tape when
assembling the flue pipe sections together.
NOTE :-
If the appliance is to be installed into a building under
construction, it is recommended that a non-corrosive metal tube of 6”
diameter be inserted into the position of the hole as specified on page 13.
15
2.8 BALANCED FLUE IN VERTICAL CONFIGURATION
2.8.1 Vertical flue configuration and components identified as shown below in
figure 14.
Fig. 14
16
Combustion
Chamber
Vertical Terminal
Locking Bands
Adaptor
Minimum Flue Height = 3 metres
Maximum Flue Height = 10 metres
For details of weather proofing
options at point of exit, please
see overpage, sections 2.8.1 to
2.8.8 for a flat roof or 2.9.1 to
2.9.6 for a pitched roof
2.8 BALANCED FLUE IN VERTICAL CONFIGURATION (FLAT ROOF)
2.8.2 Determine the position of the flue run within the property and the
termination position is correct in accordance with BS 5440. Ensure that
clearances to combustible surfaces (50mm minimum) are sufficient
where the flue run may come within close contact of joists etc.
2.8.3 For a flat roof installation the following components will need to be
ordered from Metaloterm :-
USMPG10 Mounting plate
USKB10 Locking band
US100-10/50-10/25-10 Concentic flue - quantity required
dependent upon flue height required
USDP10 Flat roof flashing
USSR10 Storm collar
2.8.4 To install the flue system therefore, make hole in roof, install the
mounting plate (USMPG10) underneath the roof and secure with
screws. (See figure 13 below).
2.8.5 Place a locking band (USKB10) in the mounting plate (USMPG10)
Put the concentric flue US100-10/50-10/25-10 through the mounting
plate and locking band until it protrudes by 400mm min, 1000mm max
through the roof. Fix the flat roof flashing (USDP10) over the flue and
fix it to the flat roof. See figure 15 below. Please ensure all joints are
taped with suitable high temperature tape when assembling the flue
pipe sections together.
2.8.6 Seal the opening between the flue and flashing with silicone rubber and
a storm collar (USSR10). See figure 15 below.
2.8.7 Install the terminal (contained within the terminal kit requested at point
of order from BFM Europe Ltd.) with a locking band and fix with 3 nuts.
2.8.8 Finish the roof covering over the flashing and weatherproof. Refer to
section 3.3 to fit the correct restrictor plate to the fire.
Fig. 15
17
Terminal
Flashing (USDP10)
Concentric flue
Mounting plate
(USMPG10)
Storm collar
(USSR10)
Concentric Flue
Protrudes 400mm
minimum, 1000mm
maximum through
roof
2.9 BALANCED FLUE IN VERTICAL CONFIGURATION (PITCHED
ROOF)
2.9.1 Determine the position of the flue run within the property and the
termination position is correct in accordance with BS 5440. Ensure that
clearances to combustible surfaces (50mm minimum) are sufficient
where the flue run may come within close contact of joists etc.
2.9.2 For a pitched roof installation the following components will need to be
ordered from Metaloterm :-
USCP10 Cover plates (pair)
USKB10 Locking band
US100-10/50-10/25-10 Concentic flue - quantity required
dependent upon flue height required
USDH10 Slope roof flashing
or USLS10 Lead slope roof flashing
USSR10 Storm collar
USDQ10 Roof support
2.9.3 To install the flue system therefore, make hole in roof, install the
pair of cover plates (USCP10) underneath the roof, put the concentric
flue US100-10/50-10/25-10 through the mounting plate and locking
band until it protrudes by 400mm min, 1000mm max through the
roof. Centre the flue and secure with the roof support (USDQ10) and
screws. (See figure 16 below). Please ensure all joints are taped with
suitable high temperature tape when assembling the flue pipe sections
together.
2.9.4 Put the slope roof flashing USDH10 (or in the case of a tiled roof the
lead flashing USLS10) over the flue and make a weather proof finish.
Seal the opening flue and flashing with the silicone rubber and the
storm collar (USSR10).
2.9.5 Install the terminal (contained within the terminal kit requested at point
of order from BFM Europe Ltd.) with a locking band and fix with 3 nuts.
2.9.6 Finish the roof covering over the flashing and weatherproof. Refer to
section 3.3 to fit the correct restrictor plate to the fire.
18
Terminal
Flashing (USDP10)
Concentric flue
Mounting plate
(USMPG10)
Storm collar
(USSR10)
Concentric Flue
Protrudes 400mm
minimum, 1000mm
maximum through
roof
Fig. 16
2.10 BALANCED FLUE UTILISING EXISTING CHIMNEY
Vertical flue configuration and components identified as shown below in figure 17
for installation into an existing chimney.
Fig. 17
NOTE
: The existing chimney must have a minimum cross-sectional area of
22,500mm2to provide sufficient air flow to fit the chimney conversion
kit.
19
Combustion
Chamber
Adaptor
Minimum
Flue
Height
= 3 metres
Maximum
Flue
Height
= 10 metres
Existing
Chimney
4” / 100mm
Flexible Flue
Liner
Outside Mounting Plate
Sliding Adaptor
Internal
Mounting
Plate
Rigid 250mm
metre section
of concentric
flue (500mm if
space allows)
Locking Band of Internal
Mounting Plate
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